Part 2

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

DISASSEMBLY(continued)

31. REMOVE CAMSHAFT
(a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
(b) Remove the 5 bearing caps.

32. REMOVE NO. 1 CAMSHAFT BEARING
Remove the No. 1 camshaft bearing.

33. REMOVE NO. 2 CAMSHAFT BEARING
(a) Remove the No. 2 camshaft bearing.

34. REMOVE CAMSHAFT TIMING SPROCKET
(a) Clamp the camshaft in a vise.
(b) Remove the flange bolt of the camshaft timing sprocket.
35. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
36. REMOVE CYLINDER HEAD SUB-ASSEMBLY
37. REMOVE CYLINDER HEAD GASKET

38. REMOVE CYLINDER BLOCK WATER JACKET SPACER
(a) Using needle-nose pliers, remove the cylinder block water jacket spacer.

NOTICE: Be sure to remove the water jacket spacer if turning the cylinder block upside down.

39. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (w/o Oil Cooler)
(a) Remove the water drain cock from the stiffening crankcase.
(b) Remove the water drain cock plug from the water drain cocks.

40. REMOVE OIL CONTROL VALVE FILTER
(a) Using an 8 mm socket hexagon wrench, remove the plug and filter.

41. REMOVE NO. 1 TAPER SCREW PLUG (w/o Oil Cooler)
(a) Remove the taper screw plug.

42. REMOVE OIL PUMP ASSEMBLY
(a) Remove the 3 bolts, oil pump and gasket.

43. REMOVE NO. 1 AND NO. 2 BALANCE SHAFT SUB-ASSEMBLY
(a) Uniformly loosen and remove the 8 bolts in the sequence shown in the illustration.

(b) Remove the No. 1 and No. 2 balance shafts.

44. REMOVE NO. 1 BALANCE SHAFT BEARING
(a) Remove the balance shaft bearings.

45. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with its tip taped, pry out the oil seal.

NOTICE: After removing the oil seal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper.

46. REMOVE STIFFENING CRANKCASE ASSEMBLY
(a) Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.

(b) Using a screwdriver, remove the crankcase by prying between the crankcase and cylinder block.

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

47. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.

(b) Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly.

HINT: The matchmarks on the connecting rods and caps are provided for ensuring the correct reassembly.

(c) Using a 12 mm socket wrench, uniformly loosen the 2 bolts.
(d) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

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

(e) 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.

48. REMOVE CONNECTING ROD BEARING
(a) Remove the connecting rod bearings.

HINT: Arrange the removed parts in the correct order.

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

HINT: Arrange the removed parts in the correct order.

50. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a screwdriver, pry out the 2 snap rings.

51. REMOVE PISTON
(a) Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).

(b) Using a plastic hammer and brass bar, 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.

52. REMOVE CRANKSHAFT
(a) Uniformly loosen and remove the 10 main bearing cap bolts in the sequence shown in the illustration.

(b) Use 2 removed main bearing cap bolts to remove the 5 main bearing caps and 5 lower bearings.

NOTICE: Insert the bolts into one of the caps. Ease the cap out by gently pulling up and applying force toward the front and back side of the cylinder block, as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block.

HINT:
- Keep the lower bearing and main bearing cap together.
- Arrange the main bearing caps in the correct order.

(c) Lift out the crankshaft.

53. REMOVE UPPER CRANKSHAFT THRUST WASHER
(a) Remove the upper thrust washers from the cylinder block.

54. REMOVE CRANKSHAFT BEARING
(a) Remove the 5 upper main bearings from the cylinder block.

HINT: Arrange the bearings in the correct order.

55. REMOVE NO. 2 CRANKSHAFT BEARING
(a) Remove the 5 lower main bearings from the 5 main bearing caps.

HINT: Arrange the bearings in the correct order.

56. REMOVE STUD BOLT

57. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, remove the bolts and oil nozzles.
58. CLEAN CYLINDER BLOCK

NOTICE: If the cylinder is washed at high temperatures, the cylinder liner will stick out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.