NR Series ENGINE MECHANICAL  ENGINE UNIT  DISASSEMBLY  

Remove the oil filler cap assembly from the cylinder head cover sub-assembly.

1.51,1.073 1.656,1.802 1.656,1.802 1.896,1.802 false 1.969,1.719 2.281,1.917 0.313,0.198 10 false *a

*a	Protective Tape

Using a screwdriver with its tip wrapped with protective tape, remove the oil filler cap gasket from the oil filler cap assembly.

Remove the bolt and engine oil level dipstick guide from the camshaft housing sub-assembly.

Remove the bolt and generator bracket from the cylinder block sub-assembly.

2.802,1.042 2.302,1.042 true 1.573,1.865 1.573,1.688 true 0.281,1.51 0.229,1.208 0.229,1.208 0.302,0.969 true 1.5,1.906 1.813,2.063 0.313,0.156 10 false *1 2.865,0.969 3.177,1.125 0.313,0.156 10 true *2 0.052,1.125 0.365,1.281 0.313,0.156 10 false *a

*1	Oil Pump Relief Valve Housing Assembly
*2	Oil Regulator Body Gasket
*a	Bolt

Remove the 2 bolts, oil pump relief valve housing assembly and oil regulator body gasket from the cylinder block sub-assembly.

0.938,1.125 1.75,1.854 1.75,1.854 2.146,1.146 true 1.698,1.885 2.01,2.042 0.313,0.156 10 false *1

*1	Cylinder Head Cover Seal Washer

Remove the 17 bolts, 2 cylinder head cover seal washers, and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

Remove the 3 gaskets from the camshaft bearing cap.

NOTICE:

As gaskets may stick to the cylinder head cover sub-assembly, be careful not to drop any of the gaskets into the engine when removing the cylinder head cover sub-assembly.

Remove the cylinder head cover gasket from the cylinder head cover sub-assembly.

Remove the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.

Using a 12 mm hexagon socket wrench, remove the oil filter union from the timing chain cover assembly.

1.125,1.719 1.615,2.427 1.615,2.427 2.177,1.698 true 1.896,3.656 1.583,4.177 1.583,4.177 2.073,3.802 true 0.719,3.365 1.552,3.365 true 1.469,4.208 1.781,4.365 0.313,0.156 10 true *a 0.385,3.281 0.698,3.438 0.313,0.156 10 true *b 1.531,2.469 1.844,2.625 0.313,0.156 10 false *c 2.365,0.125 2.979,0.281 0.615,0.156 10 false 5.93° 0.583,0.125 1.198,0.281 0.615,0.156 10 false 14.07°

*a	Timing Mark (TDC)
*b	Cutout
*c	Timing Mark

Turn the crankshaft pulley assembly until its cutout is aligned with the timing mark (TDC) of the timing chain cover assembly.

Remove the 3 bolts and engine mounting bracket RH from the timing chain cover assembly.

Remove the 17 bolts from the timing chain cover assembly.

0.656,0.635 1.719,4.25 1.719,4.25 2.854,0.938 true 0.635,2.531 1.719,4.271 1.719,4.271 2.74,2.177 true 0.594,3.802 1.719,4.271 1.719,4.271 2.75,3.938 true 1.656,4.302 1.969,4.5 0.313,0.198 10 false *a

*a	Protective Tape

Remove the timing chain cover assembly by prying between the timing chain cover assembly and cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly with a screwdriver with its tip wrapped with protective tape.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly, stiffening crankcase assembly and timing chain cover assembly.

0.5,0.365 1.625,1.323 true 0.354,1.01 0.521,1.24 true 0.313,0.198 0.625,0.354 0.313,0.156 10 false *a 0.229,0.833 0.542,0.99 0.313,0.156 10 false *b

*a	Protective Tape
*b	Wooden Block

Place the timing chain cover assembly on wooden blocks.

Remove the water inlet pipe from the water inlet.

1.5,0.698 2.063,0.698 true 0.708,0.979 1.625,0.979 true 2.104,0.646 2.417,0.802 0.313,0.156 10 true *a 0.5,0.906 0.813,1.063 0.313,0.156 10 false *b

*a	Stopper Plate
*b	Plunger
	Push

Turn the stopper plate of the No. 1 chain tensioner assembly counterclockwise to release the lock and push in the plunger.

0.75,0.896 1.625,0.896 true 0.563,0.823 0.875,0.979 0.313,0.156 10 false *a

*a

Pin

Turn the stopper plate clockwise to set the lock, and insert a pin into the stopper plate hole.

Remove the 2 bolts and No. 1 chain tensioner assembly from the cylinder head sub-assembly.

Remove the chain tensioner slipper from the cylinder block sub-assembly.

Remove the 2 bolts and timing chain guide from the cylinder block sub-assembly and cylinder head sub-assembly.

Remove the crankshaft timing sprocket from the crankshaft.

1.844,1.427 0.594,1.479 0.594,1.479 1.094,1.031 true 0.615,1.469 1.313,1.302 true 0.313,1.438 0.771,1.635 0.458,0.198 10 false SST

Using SST, hold the crankshaft pulley assembly. Then remove the oil pump drive shaft gear nut.

SST

09213-70011  (09213-70020)
09330-00021  

1.021,0.938 1.948,0.938 true 0.49,1.25 1.417,1.25 true 0.49,1.646 0.823,1.646 false 0.313,1.188 0.625,1.344 0.313,0.156 10 false *1 0.833,0.875 1.146,1.031 0.313,0.156 10 false *2 0.302,1.573 0.615,1.729 0.313,0.156 10 false *a

*1	Chain Tensioner Plate
*2	Chain Damper Spring
*a	Bolt

Remove the bolt, chain tensioner plate and chain damper spring.

0.573,0.885 0.896,0.885 false 1.167,0.521 1.49,0.521 false 0.594,1.823 0.917,1.823 false 0.385,0.823 0.698,0.979 0.313,0.156 10 false *1 0.396,1.76 0.708,1.917 0.313,0.156 10 false *2 0.969,0.458 1.281,0.615 0.313,0.156 10 false *3

*1	Oil Pump Drive Gear
*2	Oil Pump Drive Shaft Gear
*3	No. 2 Chain Sub-assembly

Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain sub-assembly.

0.469,3.667 0.417,1.927 0.417,1.927 1.333,1.552 true 0.208,1.802 0.521,1.958 0.313,0.156 10 false *a

*a	Camshaft Timing Gear Bolt (for Intake Side)

Remove the camshaft timing gear bolt (for intake side) while holding the hexagonal portion of the camshaft, and then remove the camshaft timing gear assembly.

NOTICE:

·

If the camshaft timing gear bolt (for intake side) has been struck or dropped, replace it.

·

Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.

·

Do not disassemble the camshaft timing gear assembly.

0.396,3.625 1.052,2.688 1.052,2.688 0.823,1.552 true 1.115,2.625 1.427,2.823 0.313,0.198 10 false *a

*a	Camshaft Timing Gear Bolt (for Exhaust Side)

Remove the camshaft timing gear bolt (for exhaust side) while holding the hexagonal portion of the No. 2 camshaft, and then remove the camshaft timing exhaust gear assembly.

NOTICE:

·

If the camshaft timing gear bolt (for exhaust side) has been struck or dropped, replace it.

·

Keep the camshaft timing exhaust gear assembly horizontal while removing it from the No. 2 camshaft.

·

Do not disassemble the camshaft timing exhaust gear assembly.

2.781,0.625 2.938,0.823 0.156,0.198 10 true 1 3.01,0.115 3.167,0.313 0.156,0.198 10 true 3 2.646,0.115 2.802,0.313 0.156,0.198 10 true 6 2.063,0.063 2.26,0.26 0.198,0.198 10 true 10 1.531,0.104 1.74,0.302 0.208,0.198 10 true 15 1.021,0.104 1.229,0.302 0.208,0.198 10 true 11 0,0.75 0.156,0.948 0.156,0.198 10 true 7 0.49,0.646 0.698,0.854 0.208,0.208 10 true 21 0.99,0.583 1.188,0.823 0.198,0.24 10 true 22 1.531,0.615 1.708,0.844 0.177,0.229 10 true 20 2.052,0.656 2.208,0.854 0.156,0.198 10 true 8 2.688,1.354 2.885,1.563 0.198,0.208 10 true 18 2.177,1.323 2.375,1.531 0.198,0.208 10 true 14 1.688,1.323 1.896,1.531 0.208,0.208 10 true 17 1.177,1.302 1.375,1.521 0.198,0.219 10 true 13 0.667,1.292 0.875,1.51 0.208,0.219 10 true 19 0.438,1.875 0.594,2.073 0.156,0.198 10 true 5 1.063,1.906 1.219,2.104 0.156,0.198 10 true 9 1.573,1.875 1.771,2.104 0.198,0.229 10 true 16 2.031,1.875 2.26,2.073 0.229,0.198 10 true 12 2.563,1.875 2.719,2.073 0.156,0.198 10 true 4 0.417,0.052 0.573,0.25 0.156,0.198 10 true 2

Uniformly loosen and remove the 22 bolts in the order shown in the illustration.

NOTICE:

Make sure that the camshaft and No. 2 camshaft remain level while uniformly loosening the bolts.

Remove the oil control valve filter from the camshaft housing sub-assembly.

Remove the bolt to disconnect the water valve from the camshaft housing sub-assembly.

Slide the clip and remove the No. 7 water by-pass hose from the water outlet.

Disconnect the engine coolant temperature sensor connector.

Remove the 3 bolts and water outlet from the cylinder head sub-assembly.

Remove the water outlet gasket from the water outlet.

Remove the 16 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

Remove the 16 valve stem caps from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

0.344,1.823 0.5,2.021 0.156,0.198 10 true 1 1.938,0.229 2.094,0.427 0.156,0.198 10 true 8 2.448,0.24 2.604,0.438 0.156,0.198 10 true 2 1.385,0.229 1.594,0.406 0.208,0.177 10 true 10 0.896,0.208 1.052,0.406 0.156,0.198 10 true 5 0.365,0.208 0.521,0.406 0.156,0.198 10 true 3 0.896,1.823 1.052,2.021 0.156,0.198 10 true 7 1.427,1.802 1.583,2 0.156,0.198 10 true 9 1.948,1.802 2.104,2 0.156,0.198 10 true 6 2.469,1.802 2.625,2 0.156,0.198 10 true 4

Using a 10 mm bi-hexagon socket wrench, uniformly loosen and remove the 10 cylinder head set bolts and 10 cylinder head set plate washers in several steps in the order shown in the illustration.

NOTICE:

·

Do not drop the cylinder head set plate washers into the cylinder head sub-assembly.

·

Removing the cylinder head set bolts in the incorrect order may cause warpage or cracking of the cylinder head sub-assembly.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.

Remove the oil pan drain plug and oil pan drain plug gasket from the No. 2 oil pan sub-assembly.

Remove the 10 bolts and 2 nuts from the No. 2 oil pan sub-assembly.

Insert the blade of an oil pan seal cutter between the stiffening crankcase assembly and No. 2 oil pan sub-assembly. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

NOTICE:

·

Be careful not to damage the surface of the No. 2 oil pan sub-assembly which contacts the stiffening crankcase assembly.

·

Be careful not to damage the flange of the stiffening crankcase assembly.

Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the stiffening crankcase assembly.

Remove the 2 bolts and sensor bracket from the stiffening crankcase assembly.

Uniformly loosen and remove the 10 bolts from the stiffening crankcase assembly.

1.5,3.677 2.083,4.302 2.083,4.302 2.865,3.76 true 2.021,4.323 2.333,4.521 0.313,0.198 10 false *a

*a	Protective Tape

Remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly with a screwdriver with its tip wrapped with protective tape.

NOTICE:

Be careful not to damage the contact surfaces of the stiffening crankcase assembly and cylinder block sub-assembly.

Remove the rear engine oil seal from the cylinder block sub-assembly.

NOTICE:

Be careful not to damage the crankshaft.

0.083,0.063 0.396,0.219 0.313,0.156 10 false *a

*a	Camshaft Housing Sub-assembly Top Side

Remove the 10 camshaft bearing cap setting ring pins from the camshaft housing sub-assembly.