M20C-FKS, M20D-FKS ENGINE MECHANICAL  ENGINE UNIT  DISASSEMBLY  

Slide the clip and remove the No. 1 water by-pass hose from the cylinder block sub-assembly.

Slide the clip and remove the No. 2 water by-pass hose from the water by-pass pipe sub-assembly.

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

Remove the oil filler cap gasket from the oil filler cap assembly.

1.042,1.104 0.542,1.104 0.542,1.104 0.792,0.708 false 0.031,0.198 0.344,0.396 0.313,0.198 10 false *a 2.344,1.906 2.656,2.104 0.313,0.198 10 false *b 0.25,1.01 0.708,1.208 0.458,0.198 10 false SST

*a	Hold
*b	Turn

Using SST, hold the crankshaft pulley assembly and loosen the crankshaft pulley bolt. Further loosen the crankshaft pulley bolt until 2 or 3 threads remain screwed into the crankshaft.

SST

09213-54015  
09330-00021  

1.313,1.135 1.5,1.135 false 2.052,0.188 2.167,0.188 2.167,0.188 2.198,0.635 true 1.896,0.115 2.208,0.313 0.313,0.198 10 false *1 1.021,1.042 1.479,1.24 0.458,0.198 10 false SST 0.073,2.01 0.385,2.208 0.313,0.198 10 false *a 0.906,3.177 1.219,3.375 0.313,0.198 10 false *b

*1	Crankshaft Pulley Bolt
*a	Hold
*b	Turn

Using SST and the crankshaft pulley bolt, remove the crankshaft pulley assembly and crankshaft pulley bolt.

SST

09950-50013  (09951-05010, 09952-05010, 09953-05020, 09954-05070, 09957-04010)

HINT:

Apply lubricant to the threads and end of SST.

Using an 8 mm socket wrench, remove the 2 bolts, water outlet and water outlet gasket from the cylinder head sub-assembly.

Using an 8 mm socket wrench, remove the 3 bolts, water by-pass outlet sub-assembly and water pipe outlet gasket from the cylinder head sub-assembly.

Using an 8 mm socket wrench, remove the 16 bolts and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

Remove the 7 cylinder head cover gaskets from the cylinder head cover sub-assembly.

Remove the camshaft bearing cap oil hole gasket from the No. 1 camshaft bearing cap.

2.25,0.583 2.083,0.583 2.083,0.583 1.76,0.875 true 2.313,0.51 2.531,0.698 0.219,0.188 10 true *a

*a	Protective Tape

Using a screwdriver, pry out the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.

NOTICE:

Be careful not to damage the cylinder head cover sub-assembly.

HINT:

Tape the screwdriver tip before use.

Remove the 3 bolts and engine mounting bracket RH from the No. 2 timing chain cover assembly.

Using a 10 mm hexagon socket wrench, remove the straight screw plug from the No. 2 timing chain cover assembly.

Remove the 20 bolts.

Remove the No. 2 timing chain cover assembly from the timing chain cover assembly by prying the No. 2 timing chain cover assembly with a screwdriver with its tip wrapped with protective tape.

2.073,2.854 1.469,3.573 1.469,3.573 1.979,4.167 true 5.115,1.438 5.427,1.875 5.427,1.875 5.073,2.229 true 1.25,3.469 1.469,3.646 0.219,0.177 10 true *a 5.458,1.802 5.677,1.979 0.219,0.177 10 true *a

*a

Protective Tape

-

-

NOTICE:

Be careful not to damage the contact surfaces of the No. 2 timing chain cover assembly and timing chain cover assembly.

1.771,1.031 1.729,0.188 1.729,0.188 1.615,0.188 true 2.302,0.917 2.469,0.302 2.469,0.302 2.625,0.302 true 1.417,0.094 1.729,0.292 0.313,0.198 10 false *a 2.698,0.208 3.01,0.406 0.313,0.198 10 false *b

*a	Protective Tape
*b	Wooden Block

Using a screwdriver and wooden block, pry out the timing chain cover oil seal.

NOTICE:

Do not damage the surface of the timing chain cover oil seal press fit hole.

HINT:

Tape the screwdriver tip before use.

Temporarily install the crankshaft pulley bolt.

1.25,2.5 0.719,3.031 0.719,3.031 1.146,2.875 true 6.313,2.396 6.042,2.5 6.042,2.5 6.302,2.604 true 3.396,5.75 2.063,5.75 true 1.875,5.635 2.188,5.792 0.313,0.156 10 false *1 1.115,0.25 1.427,0.406 0.313,0.156 10 false *a 6.135,0.281 6.448,0.438 0.313,0.156 10 false *b 3.917,5.167 4.229,5.323 0.313,0.156 10 false *c 5.813,2.406 6.031,2.604 0.219,0.198 10 true *d 0.49,2.938 0.708,3.135 0.219,0.198 10 true *d

*1	Crankshaft Timing Gear Key	-	-
*a	Approximately 4.63°	*b	Approximately 33.07°
*c	Approximately 2.73°	*d	Timing Mark

1.042,0.823 0.625,0.583 false 2.25,1.74 1.844,1.333 true 1.01,1.75 1.323,1.906 0.313,0.156 10 false *a 0.313,0.49 0.75,0.688 0.438,0.198 10 false SST 2.281,1.656 2.677,1.865 0.396,0.208 10 true SST

*a

Bolt

While holding the crankshaft pulley assembly with SST, remove the bolt.

SST

09213-54015  
09330-00021  

0.552,1.604 0.302,1.531 false 1.792,1.167 1.563,0.99 true 0.135,1.448 0.448,1.604 0.313,0.156 10 false *1 1.823,1.094 2.021,1.281 0.198,0.188 10 true *2

*1	Chain Tensioner Plate
*2	Chain Damper Spring

Remove the chain tensioner plate and chain damper spring.

0.719,0.792 0.896,0.792 0.896,0.792 1.333,1.271 false 0.74,1.74 0.656,1.167 0.656,1.167 0.521,1.167 false 0.594,2.865 0.552,2.521 0.552,2.521 0.396,2.521 false 0.552,0.719 0.865,0.917 0.313,0.198 10 false *1 0.333,1.073 0.646,1.271 0.313,0.198 10 false *2 0.208,2.417 0.521,2.615 0.313,0.198 10 false *3

*1	Oil Pump Drive Chain Sub-assembly
*2	Oil Pump Drive Sprocket
*3	Oil Pump Drive Shaft Sprocket

Remove the oil pump drive sprocket, oil pump drive shaft sprocket and oil pump drive chain sub-assembly.

1.667,1.219 1.958,0.875 1.958,0.875 2.115,0.875 true 2.125,0.792 2.438,0.99 0.313,0.198 10 true *a

*a	Loosen
	Turn

Hold the hexagonal portion of the exhaust camshaft sub-assembly with a wrench and turn it clockwise to loosen the chain sub-assembly between the camshaft timing exhaust gear assembly and camshaft timing gear assembly.

NOTICE:

Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube with the wrench.

1.885,0.219 2.198,0.417 0.313,0.198 10 false *a

*a	Hold
	Turn

Using a wrench, hold the hexagonal portion of the intake camshaft sub-assembly.

NOTICE:

·

Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube with the wrench.

·

Do not disassemble the camshaft timing gear assembly.

Remove the crankshaft timing sprocket and chain sub-assembly.

Using an 8 mm socket wrench, remove the bolt.

2.156,0.729 2.427,0.313 2.427,0.313 2.573,0.313 false 2.656,0.229 2.969,0.427 0.313,0.198 10 false *a

*a

Tape

Use tape to hold the plunger inside the No. 1 chain tensioner assembly.

NOTICE:

·

Make sure that the plunger, check ball assembly and spring do not come out.

·

If the No. 1 chain tensioner assembly comes apart, reinstall the parts as shown in the illustration.

3.552,1.552 3.708,1.552 3.708,1.552 3.969,1.135 false 3.042,0.938 3.302,0.521 3.302,0.521 3.458,0.521 false 2.24,0.854 2.5,0.438 2.5,0.438 2.656,0.438 false 1.563,0.521 1.771,0.281 1.771,0.281 1.906,0.281 false 3.354,1.469 3.667,1.667 0.313,0.198 10 false *a 3.552,0.427 3.865,0.625 0.313,0.198 10 false *b 2.74,0.354 3.052,0.552 0.313,0.198 10 false *c 1.99,0.188 2.302,0.385 0.313,0.198 10 false *d

*a	Plunger	*b	Check Ball Assembly
*c	Spring	*d	No. 1 Chain Tensioner Assembly Body

Remove the bolt and chain tensioner slipper from the timing chain cover assembly.

Remove the 2 bolts and No. 1 chain vibration damper from the timing chain cover assembly.

Using a wrench, hold the hexagonal portion of the exhaust camshaft sub-assembly.

NOTICE:

Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly or spark plug tube with the wrench.

0.802,0.708 0.948,0.708 0.948,0.708 1.156,1.177 false 0.427,1.313 0.542,1.313 0.542,1.313 0.542,1.771 false 0.604,0.615 0.917,0.813 0.313,0.198 10 false *1 0.25,1.208 0.563,1.406 0.313,0.198 10 false *2

*1	Camshaft Timing Exhaust Gear Assembly
*2	Camshaft Timing Valve Assembly

Remove the camshaft timing exhaust gear assembly and camshaft timing valve assembly from the exhaust camshaft sub-assembly.

Remove the 20 bolts and timing chain cover assembly from the camshaft housing sub-assembly, cylinder head sub-assembly, cylinder block sub-assembly, stiffening crankcase assembly and oil pump assembly.

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

2.063,2.385 1.583,2.25 1.583,2.25 1.938,1.958 true 1.51,4.167 1.906,3.875 true 6.01,1.167 6.219,0.969 true 6.104,2.729 6.313,2.531 true 1.375,2.156 1.573,2.344 0.198,0.188 10 true *a 1.313,4.073 1.625,4.271 0.313,0.198 10 false *a 6.25,0.854 6.458,1.052 0.208,0.198 10 true *a 6.313,2.417 6.521,2.615 0.208,0.198 10 true *a

*a

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, oil pump assembly and timing chain cover assembly.

Remove the oil nozzle valve sub-assembly from the cylinder block sub-assembly.

0.917,1.219 0.542,0.781 0.542,0.781 0.385,0.781 true 0.125,0.656 0.344,0.854 0.219,0.198 10 true *a

*a	Protective Tape

Using a screwdriver, remove the 2 crankshaft timing gear keys from the crankshaft.

NOTICE:

Be careful not to damage the crankshaft.

HINT:

Tape the screwdriver tip before use.

Using an 8 mm socket wrench, remove the 2 bolts and fuel pump lifter guide from the No. 4 camshaft bearing cap.

3.25,1.24 3.406,1.438 0.156,0.198 10 true 2 3.271,0.188 3.427,0.385 0.156,0.198 10 true 1 2.844,0.021 3,0.219 0.156,0.198 10 true 3 3.135,1.875 3.292,2.073 0.156,0.198 10 true 4 2.385,0.635 2.542,0.833 0.156,0.198 10 true 5 0.042,0.063 0.167,0.229 0.125,0.167 10 true 6 0.042,1.781 0.167,1.948 0.125,0.167 10 true 7 0.073,1.26 0.198,1.427 0.125,0.167 10 true 8 2.375,0.083 2.5,0.25 0.125,0.167 10 true 9 2.385,1.917 2.604,2.083 0.219,0.167 10 true 10 1.875,0.542 2.094,0.708 0.219,0.167 10 true 11 0.76,0.052 0.979,0.219 0.219,0.167 10 true 12 0.781,1.969 1,2.135 0.219,0.167 10 true 13 0.563,0.604 0.781,0.771 0.219,0.167 10 true 14 1.719,0.042 1.938,0.208 0.219,0.167 10 true 15 1.594,1.948 1.813,2.115 0.219,0.167 10 true 16 1.25,0.583 1.469,0.75 0.219,0.167 10 true 17

Uniformly loosen and remove the 17 bolts in the order shown in the illustration.

Using a screwdriver, remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly at the places shown in the illustration.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head sub-assembly and camshaft housing sub-assembly.

HINT:

Tape the screwdriver tip before use.

0.594,1.635 0.365,1.854 true 1.104,1.604 1.104,1.813 true 1.625,1.615 1.625,1.823 true 2.135,1.615 2.01,1.844 true 2.698,0.573 2.406,0.177 true 0.177,1.781 0.427,1.969 0.25,0.188 10 false *1 1.042,1.854 1.354,2.01 0.313,0.156 10 false *2 1.563,1.854 1.875,2.01 0.313,0.156 10 false *3 2.229,0.083 2.542,0.24 0.313,0.156 10 false *4 1.927,1.875 2.24,2.031 0.313,0.156 10 false *3 0.073,1.073 0.24,1.26 0.167,0.188 10 false 1 2.177,1.792 2.344,1.979 0.167,0.188 10 true 2 3.021,1.396 3.188,1.583 0.167,0.188 10 true 3 1.406,0.594 1.573,0.781 0.167,0.188 10 true 4 0.604,1.323 0.771,1.51 0.167,0.188 10 true 5 2.521,0.625 2.688,0.813 0.167,0.188 10 true 6 1.719,1.448 1.885,1.635 0.167,0.188 10 true 7 1.99,0.531 2.156,0.719 0.167,0.188 10 true 8 1.271,1.469 1.438,1.656 0.167,0.188 10 true 9

*1	No. 1 Camshaft Bearing Cap
*2	No. 2 Camshaft Bearing Cap
*3	No. 3 Camshaft Bearing Cap
*4	No. 4 Camshaft Bearing Cap

Remove the 9 bolts in the order shown in the illustration.

Remove the intake camshaft sub-assembly from the camshaft housing sub-assembly.

Remove the exhaust camshaft sub-assembly from the camshaft housing sub-assembly.

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

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.

Using an 8 mm socket wrench, remove the 2 bolts, No. 1 water by-pass pipe and gasket from the cylinder head sub-assembly.

0.49,1.948 0.646,2.146 0.156,0.198 10 true 1 2.927,0.24 3.083,0.438 0.156,0.198 10 true 2 0.5,0.24 0.656,0.438 0.156,0.198 10 true 3 2.875,1.958 3.031,2.156 0.156,0.198 10 true 4 1.031,1.938 1.396,2.135 0.365,0.198 10 true 5, *a 2.208,0.313 2.573,0.521 0.365,0.208 10 true 6, *a 1.031,0.281 1.427,0.49 0.396,0.208 10 true 7, *a 2.219,1.927 2.604,2.115 0.385,0.188 10 true 8, *a 1.604,0.302 1.979,0.5 0.375,0.198 10 true 9, *a 1.604,1.938 2.052,2.115 0.448,0.177 10 true 10, *a

*a	Plate Washer
	Front of Engine

Using a 12 mm socket wrench, uniformly loosen the 10 cylinder head set bolts in the order shown in the illustration. Remove the 10 cylinder head set bolts and 6 plate washers.

NOTICE:

·

Be careful not to drop the plate washers into the cylinder head sub-assembly.

·

Warpage or cracking of the cylinder head sub-assembly may result from removing the cylinder head set bolts in the incorrect order.

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 exhaust side of the cylinder block sub-assembly.

NOTICE:

Be sure to remove the cylinder block water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block sub-assembly is inverted.

2.646,1.5 2.844,1.708 0.198,0.208 10 true *a 1.042,2.01 1.313,2.177 0.271,0.167 10 false *a

*a

Nut

Remove the 12 bolts and 2 nuts.

Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut through the applied sealer and remove the oil pan sub-assembly.

NOTICE:

·

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

·

Be careful not to damage the oil pan sub-assembly flange.

Using an 8 mm socket wrench, remove the bolt, oil strainer sub-assembly and oil strainer gasket from the stiffening crankcase assembly.

Remove the 6 bolts and engine balancer assembly from the stiffening crankcase assembly.

NOTICE:

Do not disassemble the engine balancer assembly.

Remove the clip from the crankcase cap assembly.

Remove the 7 bolts.

Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly at the places shown in the illustration.

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Using a 10 mm hexagon socket wrench, remove the straight screw plug and gasket from the stiffening crankcase assembly.

Remove the bolt and wire harness clamp bracket from the stiffening crankcase assembly.

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