Disassembly

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

DISASSEMBLY

HINT:
^ Thoroughly clean all parts to be assembled.
^ Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
^ Replace all gaskets, O-rings and oil seals with new parts.

1. REMOVE SPARK PLUG
2. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH
3. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
4. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
5. REMOVE NO. 2 TIMING BELT COVER SUB-ASSEMBLY
6. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
7. REMOVE IDLER PULLEY ASSEMBLY
8. REMOVE CRANKSHAFT PULLEY
9. REMOVE NO. 1 TIMING BELT COVER
10. REMOVE CRANKSHAFT POSITION SENSOR PLATE
11. REMOVE TIMING GEAR COVER SPACER
12. REMOVE TIMING BELT
13. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
(a) Using a 10 mm hexagon wrench, remove the bolt, idler and plate washer.

14. REMOVE NO. 2 TIMING BELT IDLER SUB-ASSEMBLY
(a) Remove the bolt and idler.

15. REMOVE CRANKSHAFT TIMING PULLEY
(a) Using SST, remove the timing pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010)

NOTICE: Do not turn the timing pulley.

16. REMOVE SEMICIRCULAR PLUG
17. REMOVE CAMSHAFT TIMING PULLEY SUB-ASSEMBLY RH
18. REMOVE CAMSHAFT TIMING PULLEY SUB-ASSEMBLY LH
19. REMOVE REAR NO. 2 TIMING BELT PLATE RH
20. REMOVE REAR TIMING BELT PLATE RH
21. REMOVE REAR NO. 2 TIMING BELT PLATE LH
22. REMOVE REAR TIMING BELT PLATE LH
23. REMOVE CAMSHAFT
24. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY
25. REMOVE CYLINDER HEAD SUB-ASSEMBLY

RH Bank:

(a) Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes, in the sequence shown in the illustration.

RH Bank:

NOTICE:
^ Cylinder head warpage or cracking could result from removing bolts in the incorrect order.
^ Be careful not to drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

RH Bank:

LH Bank:

(a) Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes, in the sequence shown in the illustration.

LH Bank:

(b) Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

HINT: If the cylinder head cannot be removed, pry between the cylinder head and cylinder block with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

28. REMOVE NO. 2 CYLINDER HEAD GASKET
29. REMOVE WATER PUMP ASSEMBLY
30. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
31. REMOVE OIL PAN BAFFLE PLATE
32. REMOVE OIL PAN SUB-ASSEMBLY
33. REMOVE OIL STRAINER SUB-ASSEMBLY
34. REMOVE OIL PUMP ASSEMBLY

35. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 7 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and crankshaft bearing cap.
(c) Remove the O-ring.

36. REMOVE VALVE LIFTER
37. REMOVE INTAKE VALVE
38. REMOVE EXHAUST VALVE
39. REMOVE VALVE STEM OIL SEAL
40. REMOVE CAMSHAFT TIMING TUBE ASSEMBLY
41. REMOVE CAMSHAFT SUB GEAR

42. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Remove the RH and LH drain cocks.
(b) Remove the 2 nuts.
(c) Pry out the seal plate.

43. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.160 to 0.290 mm (0.0063 to 0.0138 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
Connecting rod thickness: 22.880 to 22.920 mm (0.9008 to 0.9024 in.)

44. INSPECT CONNECTING ROD OIL CLEARANCE

(a) Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
(b) Remove the 2 connecting rod cap bolts.

(c) Using the removed connecting rod cap bolts, remove the connection rod cap and lower bearing by wiggling the connecting rod cap right and left.

HINT: Keep the lower bearing inserted with the connecting rod cap.

(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

(f) Lay a strip of Plastigage across the crank pin.

(g) Install the connecting rod cap with the 2 bolts.
(h) Remove the 2 bolts, connecting rod cap and lower bearing.

(i) Measure the Plastigage at its widest point.
Standard oil clearance: 0.021 to 0.047 mm (0.0008 to 0.0019 in.)
Maximum oil clearance: 0.065 mm (0.0026 in.)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

HINT: If replacing a standard bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the connecting rod cap and crankshaft, and then select the bearing with the same number as the total. There are 6 sizes of standard bearings, marked 2, 3, 4, 5, 6 and 7.

Standard Bearings:

EXAMPLE: Connecting rod cap "3" + Crankshaft "1" = "4" (Use bearing "4")

Connecting rod big end inside diameter:

Crankshaft crank pin diameter:

Standard sized bearing center wall thickness (Part 1):

Standard sized bearing center wall thickness (Part 2):

(j) Completely remove the Plastigage.

45. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.020 to 0.220 mm (0.0008 to 0.0087 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set.
Thrust washer thickness: 2.440 to 2.490 mm (0.0961 to 0.0980 in.)

46. INSPECT CRANKSHAFT OIL CLEARANCE

(a) Remove the 10 crankshaft bearing cap bolts.

(b) Uniformly loosen and remove the 20 crankshaft bearing cap bolts in the sequence shown in the illustration.

(c) Using 2 screwdrivers, pry out the crankshaft bearing caps, and remove the 5 crankshaft bearing caps, 5 lower bearings and 2 lower thrust washers (No. 3 crankshaft bearing cap only).

NOTICE: Be careful not to damage the cylinder block.

HINT:
^ Keep the lower bearing and cap together.
^ Be sure to arrange the bearing caps and lower thrust washers in such a way that they can be reinstalled exactly as before.

(d) Lift out the crankshaft.
(e) Remove the 2 upper thrust washers.

HINT:
^ Be sure to arrange the removed upper thrust washers in such a way that they can be reinstalled exactly as before.
^ Keep the upper bearings together with the cylinder block.

(f) Clean each crankshaft journal and bearing.
(g) Check each crankshaft journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

(h) Install the 10 crankshaft bearings and 5 crankshaft bearing caps with the 30 bolts. Do not install the crankshaft.

(i) Using a cylinder gauge, measure the inside diameter of the crankshaft bearing.
Bearing inside diameter: 66.986 to 67.000 mm (2.6372 to 2.6378 in.)
(j) Measure the diameter of the crankshaft journal.

(k) Subtract the crankshaft journal diameter measurement from the crankshaft bearing inside diameter measurement.

Standard clearance:

Maximum clearance:

If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

HINT: If replacing a standard bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, and then refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings. For No. 1 and No. 5 position bearings, use bearings marked 3, 4, 5, 6 and 7. For other position bearings, use bearings marked 1, 2, 3, 4 and 5.
A = Cylinder block
B = Crankshaft

No. 1, No. 5:

EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "4" (Upper), "5" (Lower))

Other (Part 1):

Other (Part 2):

EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "2" (Upper), "3" (Lower))

Cylinder block crankshaft journal bore diameter (A):

Crankshaft journal diameter (B):

Standard bearing center wall thickness (Part 1):

Standard bearing center wall thickness (Part 2):

Other:

(l) Remove the 30 bolts, 5 crankshaft bearing caps and 5 lower crankshaft bearings.
(m) Remove the 5 upper crankshaft bearings from the cylinder block.

HINT: Be sure to arrange the bearing caps, bearings and thrust washers in such a way that they can be reinstalled exactly as before.

47. REMOVE PISTON AND CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

HINT:
^ Keep the bearings, connecting rod and cap together.
^ Be sure to arrange the removed piston and connecting rod assemblies in such a way that they can be reinstalled exactly as before.

48. REMOVE PISTON SUB-ASSEMBLY WITH PIN

(a) Check the piston and piston pin.
(1) Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin with a new piston and pin set.

(b) Using a piston ring expander, remove the No. 1 and No. 2 piston rings.

HINT: Be sure to arrange the removed piston rings in such a way that they can be reinstalled exactly as before.

(c) Remove the 2 side rails and expander by hand.

(d) Using a small screwdriver, pry out the 2 snap rings.

(e) Gradually heat the piston to approximately 60°C (140°F).

(f) Using a plastic-faced hammer and brass bar, lightly tap out the piston and pin. Then remove the connecting rod.

HINT:
^ The piston and pin are a matched set.
^ Be sure to arrange the removed pistons, pins, rings, connecting rods and bearings in such a way that the parts can be reinstalled exactly as before.