Section02ENGINE
Subsection 07 (TOP END)
TROUBLESHOOTING
Before completely disassembling the engine, pro-
ceed with an engine leak test. Refer to LEAK
TEST.
GENERAL
During assembly/installation, use torque values
and service products as shown in exploded
view(s).
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
must strictly be adhered to. Locking de-
vices (e.g.: locking tabs, elastic stop nuts,
self-locking fasteners, cotter pin, etc.) must
be installed or replaced with new ones where
specified. If the efficiency of a locking device
is impaired, it must be renewed.
It is not mandatory to remove engine from chas-
sis for top end repair. To proceed with engine re-
moval, refer to REMOVAL AND INSTALLATION.
COMPONENT REMOVAL WITH
THEENGINEINSTALLED
The following engine components can be re-
moved with engine on vehicle such as:
– cylinder head
– cylinder block
– piston(s)
– reed valve(s).
NOTE: Since the cylinder block is heavy and the
working space is limited, being assisted by some-
one will ease the cylinder block removal/installa-
tion.
DISASSEMBLY
RAVE System
Remove RAVE system. Refer to RAVE SYSTEM.
Fuel Rail
Remove fuel rail no. 10. Refer to ENGINE MAN-
AGEMENT.
REED Valve
Unscrew reed valve screws no. 1 then remove
reed valves.
A35C0UA
Cylinder Head
Remove the knock sensor no. 2.
Disconnect the temperature sensor connector.
Unplug coolant hose from upper thermostat hous-
ing no. 3.
Unscrew cylinder block head screws no. 4.
Remove the cylinder head no. 5.
A35C0VA
If it is necessary to withdraw the removable com-
bustion chamber no. 14, push out by spark plug
hole area.
mmr2005-117 53
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