ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap sub-assembly and oil filler cap gasket.

  2. REMOVE SPARK PLUG

    Click here

  3. REMOVE OIL PAN DRAIN PLUG


    1. A01W2R3

      Remove the oil pan drain plug and oil pan drain plug gasket.

  4. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A01W0WH

      Remove the ventilation valve sub-assembly.

  5. REMOVE VVT SENSOR

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  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Click here

  7. REMOVE CRANK POSITION SENSOR

    Click here

  8. REMOVE NO. 1 OIL PIPE


    1. A01W5K9E01
      Text in Illustration
      *1 Oil Pipe Union

      Remove the 2 oil pipe unions, 3 gaskets and No. 1 oil pipe.

    2. Remove the oil control valve filter LH.

  9. REMOVE OIL PIPE


    1. A01W5D1E12
      Text in Illustration
      *1 Oil Pipe Union
      *2 Bolt

      Remove the bolt.

    2. Remove the 2 oil pipe unions, 3 gaskets and oil pipe.

    3. Remove the oil control valve filter RH.

  10. REMOVE TAPER SCREW PLUG

    Tech Tips

    Perform this operation only when a taper screw plug is installed.


    1. A01W4M1

      Remove the taper screw plug from the cylinder block sub-assembly.

  11. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

    A01W051E03
    Text in Illustration
    *A for Bank 1
    *B for Bank 2

    1. for Bank 1:


      1. Remove the cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.

      2. Remove the cylinder block water drain cock plug from the cylinder block water drain cock sub-assembly.

    2. for Bank 2:

      Tech Tips

      Perform this operation only when a cylinder block water drain cock sub-assembly is installed.


      1. Remove the cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.

      2. Remove the cylinder block water drain cock plug from the cylinder block water drain cock sub-assembly.

  12. REMOVE OIL FILTER CAP ASSEMBLY

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  13. REMOVE CRANKSHAFT PULLEY

    Click here

  14. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler)

    Click here

  15. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)


    1. A01W2PD

      Remove the 3 bolts, 3 nuts, gasket and No. 1 oil cooler bracket together with the oil cooler pipe.

    2. Using an E7 "TORX" socket wrench, remove the stud bolt.

    3. A01W5CGE02
      Text in Illustration
      *1 Nut
      *2 Bolt

      Remove the bolt, 2 nuts, No. 1 oil cooler bracket, and gasket.

    4. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.

  16. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. w/ Oil Cooler:


      1. A01W1NN

        Remove the engine oil level dipstick guide.

    2. w/o Oil Cooler:


      1. A01W33P

        Remove the bolt and engine oil level dipstick guide.

    3. A01W0HK

      Remove the O-ring.

  17. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A01W53T

      Remove the 6 bolts and No. 1 front engine mounting bracket LH.

    2. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.

  18. REMOVE WATER INLET HOUSING


    1. A01W2K4

      Remove the 2 nuts, water inlet and thermostat.

    2. Remove the gasket.

    3. Remove the 2 stud bolts.

    4. Slide the clip and disconnect the No. 1 water bypass hose from the water inlet housing.

    5. A01VZBCE11
      Text in Illustration
      *1 Nut
      *2 Bolt

      Remove the drain cock plug.

    6. Remove the drain cock assembly.

    7. Remove the 2 bolts, nut, and water inlet housing.

    8. A01W1WU

      Remove the 2 O-rings.

  19. REMOVE WATER OUTLET


    1. A01W16FE04
      Text in Illustration
      *A w/ Oil Cooler
      *B w/o Oil Cooler
      *1 Nut
      *2 Bolt

      Remove the 2 bolts, 4 nuts and water outlet.

    2. A01W03F

      Remove the 2 gaskets and O-ring.

  20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01W2DKE03
      Text in Illustration
      *1 Seal Washer

      Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.

    2. A01W56A

      Remove the 3 gaskets.

  21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01VZRVE01
      Text in Illustration
      *1 Baffle Plate
      *2 Seal Washer

      Remove the 12 bolts, seal washer, cylinder head cover sub-assembly LH and No. 2 cylinder head cover gasket.

      Note

      The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the cylinder head cover sub-assembly LH.

    2. A01W2S9

      Remove the 3 gaskets.

  22. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01W4Z0E08
      Text in Illustration
      *1 Nut

      Remove the 16 bolts and 2 nuts.

    2. A01W4L1

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

      Note

      Be careful not to damage the contact surfaces of the oil pan sub-assembly and No. 2 oil pan sub-assembly.

    3. Using an E6 "TORX" socket wrench, remove the 2 stud bolts.

  23. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01W0POE09
      Text in Illustration
      *1 Bolt
      *2 Nut

      Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.

    2. Using an E6 "TORX" socket wrench, remove the 2 stud bolts.

  24. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01VZVBE16
      Text in Illustration
      *A w/o Oil Cooler
      *B w/ Oil Cooler
      *1 Nut

      Remove the 16 bolts and 2 nuts.

      Tech Tips

      Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

    2. A01W367E09
      Text in Illustration
      *a Protective Tape

      Remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly with a screwdriver.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

    3. A01W57H

      Remove the 2 O-rings.

    4. w/ Oil Cooler:


      1. Using an E8 "TORX" socket wrench, remove the 4 stud bolts.

    5. w/o Oil Cooler:


      1. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.

  25. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01W37L

      Remove the 7 bolts and No. 1 oil pan baffle plate.

  26. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01W2WA

      Remove the 6 bolts.

    2. A01W4ACE02
      Text in Illustration
      *a Protective Tape
      B001O8N Pry

      Using a screwdriver, pry out the engine rear oil seal retainer.

      Note

      Be careful not to damage the engine rear oil seal retainer.

      Tech Tips

      Tape the screwdriver tip before use.

  27. REMOVE ENGINE REAR OIL SEAL


    1. A01W415E10
      Text in Illustration
      *a Protective Tape
      *b Wooden Block

      Place the engine rear oil seal retainer on wooden blocks.

    2. Using a screwdriver and a hammer, tap out the engine rear oil seal.

      Note

      Be careful not to damage the engine rear oil seal retainer.

      Tech Tips

      Tape the screwdriver tip before use.

  28. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01W1VS

      Remove the 16 bolts, engine water pump assembly and water pump gasket.

  29. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01W1NLE02
      Text in Illustration
      *1 Nut

      Remove the 15 bolts and 2 nuts as shown in the illustration.

    2. A01W4LJE10
      Text in Illustration
      *a Protective Tape

      Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

    3. Remove the 4 bolts, timing chain cover plate and timing chain cover plate gasket.

    4. A01VZJ2

      Remove the gasket.

  30. REMOVE TIMING CHAIN CASE OIL SEAL

    Click here

  31. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily tighten the crankshaft pulley set bolt.

    2. A01W3JCE10
      Text in Illustration
      *a Sensor Plate
      *b Center Line
      *c Timing Mark

      Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression).

    3. A01W3CGE01
      A01VZD6E01

      Check that the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are aligned with the timing marks of the camshaft bearing caps as shown in the illustration.

      Text in Illustration
      *a Timing Mark

      If not, turn the crankshaft 1 revolution (360°) clockwise and align the timing marks as above.

  32. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01VZTXE17
      Text in Illustration
      *a Plunger
      *b Stopper Plate
      *c Pin

      Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.

    2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate hole.

    3. A01W2KN

      Remove the 2 bolts and No. 1 chain tensioner assembly.

  33. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  34. REMOVE CHAIN SUB-ASSEMBLY


    1. A01W2MSE07
      Text in Illustration
      *1 Sensor Plate
      *a Center Line
      *b Timing Mark

      Turn the crankshaft 10° counterclockwise to loosen the chain sub-assembly of the crankshaft timing sprocket.

    2. Remove the crankshaft pulley set bolt.

    3. A01W5L0

      Remove the chain sub-assembly from the crankshaft timing sprocket and place it on the crankshaft.

    4. A01W0EVE01
      Text in Illustration
      *A for Bank 1

      Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) and set it as shown in the illustration.

      Note

      Be sure to loosen the chain sub-assembly between the banks.

    5. Remove the chain sub-assembly.

  35. REMOVE IDLE SPROCKET ASSEMBLY


    1. A01W57F

      Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft.

  36. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01W1S0

      Remove the 2 bolts and No. 1 chain vibration damper.

  37. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. Remove the 2 No. 2 chain vibration dampers.

  38. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01W2KR

      Remove the crankshaft timing sprocket from the crankshaft.

    2. Remove the 2 keys from the crankshaft.

  39. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)

    Click here

  40. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

    Click here

  41. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

    Click here

  42. REMOVE CAMSHAFT

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  43. REMOVE NO. 2 CAMSHAFT

    Click here

  44. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

    Click here

  45. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)

    Click here

  46. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

    Click here

  47. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

    Click here

  48. REMOVE NO. 3 CAMSHAFT

    Click here

  49. REMOVE NO. 4 CAMSHAFT

    Click here

  50. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

    Click here

  51. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

    Click here

  52. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    Click here

  53. REMOVE VALVE STEM CAP

    Click here

  54. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

    Click here

  55. REMOVE CYLINDER HEAD GASKET RH

    Click here

  56. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

    Click here

  57. REMOVE CYLINDER HEAD GASKET LH

    Click here

  58. REMOVE WATER INLET PIPE


    1. Slide the clip and disconnect the No. 1 water bypass hose from the water inlet pipe.

    2. A01W4ZHE08
      *A w/o Oil Cooler
      *B w/ Oil Cooler

      Remove the 2 bolts and water inlet pipe.