Part 2

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

DISASSEMBLY(continued)

31. REMOVE NO.2 CHAIN SUB-ASSEMBLY
(a) Remove the bolt, balance shaft drive gear shaft and balance shaft drive gear.
(b) Remove the crankshaft timing sprocket No.2 and chain.

32. REMOVE NO. 4 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts and vibration damper No.4.

33. REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY
(a) Remove the 2 pulley set keys from the crankshaft.

34. REMOVE OIL FILTER SUB-ASSEMBLY
(a) Using SST, remove the oil filter.
SST 09228-07501

(b) Using a 27 mm socket wrench, remove the oil filter union.

35. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY
(a) Remove the 2 bolts and nut from the oil filter bracket.
(b) Remove the 2 screw plugs and 2 gaskets from the oil filter bracket.

(d) Using a hexagon wrench, remove the oil filter bracket union.

36. REMOVE NO. 1 WITH HEAD TAPER SCREW PLUG
(a) Remove the taper screw plug from the cylinder block.

37. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver with its tip taped, pry out the oil seal retainer.

HINT: Tape the screwdriver tip before use.

38. REMOVE VALVE STEM CAP
(a) Remove the valve stem caps from the cylinder head.

HINT: Arrange the removed parts in the correct order.

39. REMOVE VALVE LASH ADJUSTER ASSEMBLY
(a) Remove the valve lash adjusters from the cylinder head.

HINT: Arrange the removed parts in the correct order.

40. REMOVE INTAKE VALVE
(a) Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.
SST 09202-70020 (09202-00010)

(b) Remove the retainer, compression spring, and valve.

HINT: Arrange the removed parts in the correct order.

41. REMOVE EXHAUST VALVE
(a) Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.
SST 09202-70020 (09202-00010)

(b) Remove the retainer, compression spring, and valve.

HINT: Arrange the removed parts in the correct order.

42. REMOVE VALVE STEM OIL SEAL
(a) Using needle-nose pliers, remove the oil seals.
43. REMOVE VALVE SPRING SEAT
(a) Remove the valve spring seats from the cylinder head.

44. REMOVE OIL CONTROL VALVE FILTER
(a) Using an 8 mm hexagon wrench, remove the screw plug.
(b) Remove the oil control valve filter and gasket.

45. REMOVE NO. 1 WITH HEAD STRAIGHT SCREW PLUG
(a) Using a 10 mm hexagon wrench, remove the 3 screw plugs and 3 gaskets.

NOTICE: If water leaks from the w/ head straight screw plug No.1 or the plug corrodes, replace it.

46. REMOVE NO. 2 WITH HEAD STRAIGHT SCREW PLUG
(a) Using a 19 mm hexagon wrench, remove the screw plug and gasket.

NOTICE: If water leaks from the w/ head straight screw plug No.2 or the plug corrodes, replace it.

47. REMOVE CRANKSHAFT BEARING

48. REMOVE PISTON SUB-ASSEMBLY WITH 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 bearing, connecting rod and cap together.
^ Arrange the piston and connecting rod assemblies in the correct order.

49. REMOVE CONNECTING ROD BEARING

HINT: Arrange the removed parts in the correct order.

50. REMOVE CRANKSHAFT
(a) Uniformly loosen the 10 bearing cap bolts, in several steps, in the sequence shown in the illustration.

HINT:
^ Keep the lower bearings and crankshaft bearing caps together.
^ Arrange the thrust washers in the correct order.

(b) Lift out the crankshaft.

(c) Remove the upper bearings and upper thrust washers from the cylinder block.

HINT: Arrange the main bearing caps, bearings and thrust washers in the correct order.

51. REMOVE CRANKSHAFT BEARING

HINT: Arrange the removed parts in the correct order.

52. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression rings.
(b) Using a piston ring expander, remove the oil ring rail.
(c) Remove the oil ring expander by hand.

HINT: Arrange the piston rings in the correct order.

53. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Remove the water drain cock sub-assembly from the cylinder block.
(b) Remove the water drain cock plug from the water drain cock sub-assembly.

54. REMOVE WITH PIN PISTON SUB-ASSEMBLY
(a) Check the fitting condition between 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 as a set.

(b) Disconnect the connecting rod from the piston.
(1) Using a screwdriver, pry off the snap rings from the piston.

(2) Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).

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

HINT:
^ The piston and pin are a matched set.
^ Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

55. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, remove the oil nozzles.

56. REMOVE NO.1 BALANCE SHAFT
(a) Remove the bolt.

(b) Remove the balance shaft from the cylinder block.

NOTICE: When removing the balance shaft, make sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block side.

57. REMOVE NO. 1 BALANCE SHAFT DRIVEN GEAR
(a) Mount the head portion of the balance shaft in a vise.

NOTICE: Be careful not to damage the balance shaft.

(b) Remove the bolt.
(c) Remove the balance shaft driven gear No.1 (*1), sliding key (*2), balance shaft thrust washer No.1 (*3) and balance shaft thrust spacer (*4).

58. REMOVE NO.2 BALANCE SHAFT
(a) Remove the 2 bolts.

59. REMOVE NO. 2 BALANCE SHAFT DRIVEN GEAR
(a) Mount the head portion of the balance shaft in a vise.

NOTICE: Be careful not to damage the balance shaft.

(b) Remove the bolt.
(c) Remove the balance shaft driven gear No.2 (*1) and balance shaft thrust washer No.2 (*2).