ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. B006XHP

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

    2. B006WXB

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

  2. REMOVE SPARK PLUG

    Click here

  3. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

    Click here

  4. REMOVE TAPER SCREW PLUG


    1. B00709H

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

  5. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

    B0071NC

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

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

  6. REMOVE CRANKSHAFT PULLEY

    Click here

  7. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. B006Y14

      Remove the 7 bolts and front No. 1 engine mounting bracket LH from the timing chain cover assembly.

  8. REMOVE WATER BY-PASS HOSE


    1. B006Z6Q

      Slide the 2 clips and remove the water by-pass hose from the water inlet pipe and water inlet with thermostat sub-assembly.

  9. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

    Click here

  10. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)

    Click here

  11. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)

    Click here

  12. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)

    Click here

  13. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)

    Click here

  14. REMOVE VVT SENSOR (for Intake Side of Bank 1)

    Click here

  15. REMOVE VVT SENSOR (for Exhaust Side of Bank 1)

    Click here

  16. REMOVE VVT SENSOR (for Intake Side of Bank 2)

    Click here

  17. REMOVE VVT SENSOR (for Exhaust Side of Bank 2)

    Click here

  18. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR

    Click here

  19. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  20. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  21. REMOVE WATER OUTLET


    1. B0070T0C01
      B006Z38 Bolt
      B006ZY0 Nut

      Remove the 4 bolts, 2 nuts and water outlet from the cylinder head sub-assembly and cylinder head LH.

    2. B004MKL

      Remove the 2 No. 2 water inlet housing gaskets from the water outlet.

  22. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B0070OZ

      Remove the 2 clips and No. 1 engine cover sub-assembly from the cylinder head cover sub-assembly.

    2. B006Y99

      Remove the 13 bolts and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

    3. B006Y06

      Remove the camshaft bearing cap oil hole gasket from the camshaft bearing cap.

    4. B006ZOM

      Remove the 3 cylinder head cover gaskets from the cylinder head cover sub-assembly.

  23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. B006ZUE

      Remove the No. 1 V-bank cover bracket from the cylinder head cover sub-assembly LH.

    2. B00703D

      Remove the 14 bolts and cylinder head cover sub-assembly LH from the camshaft housing sub-assembly LH.

    3. B006XUA

      Remove the camshaft bearing cap oil hole gasket LH from the camshaft bearing cap.

    4. B006XC6

      Remove the 3 No. 2 cylinder head cover gaskets from the cylinder head cover sub-assembly LH.

  24. REMOVE SPARK PLUG TUBE GASKET


    1. B006WSOC01
      *a Protective Tape

      Using a screwdriver as shown in the illustration, deform each spark plug tube gasket inwards and remove the 6 spark plug tube gaskets from the cylinder head cover sub-assembly and cylinder head cover sub-assembly LH.

  25. REMOVE OIL PAN DRAIN PLUG


    1. B006Y0Z

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

  26. REMOVE OIL FILTER CAP ASSEMBLY

    Click here

  27. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  28. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. B006XX7

      Remove the 15 bolts and 2 nuts from the No. 2 oil pan sub-assembly.

    2. B006XA6

      Insert the blade of an 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 pans.

  29. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B006ZL1

      Remove the 2 nuts and oil strainer sub-assembly from the timing chain cover assembly.

    2. B006XLH

      Remove the oil strainer gasket from the oil strainer sub-assembly.

  30. REMOVE ENGINE OIL LEVEL SENSOR

    Click here

  31. REMOVE OIL PAN SUB-ASSEMBLY

    Click here

  32. REMOVE OIL FILTER BRACKET CLIP


    1. B006X2M

      Remove the oil filter bracket clip from the oil pan sub-assembly.

  33. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. B006Z13

      Remove the 8 bolts and No. 1 oil pan baffle plate from the crankshaft bearing cap set bolt.

  34. REMOVE TIMING CHAIN COVER PLATE


    1. B006WZQ

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

  35. REMOVE TIMING CHAIN CASE OIL SEAL

    Click here

  36. REMOVE TIMING CHAIN COVER ASSEMBLY

    Click here

  37. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. B0071V2

      Remove the 7 bolts, engine water pump assembly and water pump gasket from the timing chain cover assembly.

  38. SET NO. 1 CYLINDER TO TDC (COMPRESSION)


    1. Temporarily tighten the crankshaft pulley set bolt to the crankshaft.

    2. B006YSOC01
      *a Center Line
      *b Key Groove

      Turn the crankshaft clockwise to align the timing mark of the crankshaft timing sprocket key groove chase position with the center line of the block bore (for Bank 1) (TDC / compression).

    3. 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.

      B007151C02
      *a Timing Mark *b Viewpoint

      Note


      • Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear assembly and each camshaft timing exhaust gear assembly.

      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

      Tech Tips


      • If not aligned, turn the crankshaft 1 revolution (360°) clockwise and align the timing marks as shown in the illustration.

      • B0070BZN01

        For the camshaft or No. 3 camshaft sub-assembly:

        Be sure to check the mark (A) at the point where the marks (B), (C) and (D) are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

  39. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B006Y3QC01
      *a Plunger
      *b Stopper Plate
      *c Pin

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

    2. Turn the stopper plate counterclockwise to set the lock, and insert a 1.0 mm (0.0394 in.) diameter pin into the hole of the stopper plate.

    3. B006XW0

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

  40. REMOVE CHAIN TENSIONER SLIPPER


    1. B006Y3L

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

  41. REMOVE CHAIN SUB-ASSEMBLY


    1. B006XORC01
      *a Center Line
      *b Mark
      *c Key Groove

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

    2. Remove the crankshaft pulley set bolt from the crankshaft.

    3. B0070H2

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

    4. B006XJKC01
      *A for Bank 1

      Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) so that it is positioned as shown in the illustration.

      Note

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

    5. Remove the chain sub-assembly from the engine assembly.

  42. REMOVE IDLE SPROCKET ASSEMBLY


    1. B007079

      Using a 10 mm hexagon socket wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft from the cylinder block sub-assembly.

  43. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B006Y1E

      Remove the 2 bolts and No. 1 chain vibration damper from the cylinder head LH and cylinder block sub-assembly.

  44. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. B0071R1

      Remove the 2 No. 2 chain vibration dampers from the cylinder head LH and cylinder head sub-assembly.

  45. REMOVE CRANKSHAFT TIMING SPROCKET


    1. B006YVJ

      Remove the crankshaft timing sprocket from the crankshaft.

  46. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. B00705T

      Remove the 2 crankshaft timing gear keys from the crankshaft.

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


    1. B006WYEC01
      *a Pin
      *b Plunger
      B006ZY0 Push

      While raising the No. 2 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the hole to secure the No. 2 chain tensioner assembly.

    2. B006YF2C01
      *a Hold
      B006Z38 Turn

      Using a wrench to hold the hexagonal portion of camshaft, loosen the camshaft timing gear bolt of the camshaft timing gear assembly.

      Note


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

      • Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.

      • If the camshaft timing gear bolt has been struck or dropped, replace it.

    3. B0071JPC01
      *a Hold
      B006Z38 Turn

      Using a wrench to hold the hexagonal portion of No. 2 camshaft, loosen the camshaft timing gear bolt of the camshaft timing exhaust gear assembly.

      Note


      • Be careful not to damage the No. 2 camshaft, camshaft housing sub-assembly or spark plug tube with wrench.

      • Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.

      • If the camshaft timing gear bolt has been struck or dropped, replace it.

    4. Remove the 2 camshaft timing gear bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly together with the No. 2 chain sub-assembly.

  48. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B006ZB9

      Remove the bolt and No. 2 chain tensioner assembly from the camshaft housing sub-assembly.

  49. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. B006Y9SC01
      *a Straight Pin
      *b Front View
      *c 45°

      Check that the camshaft and No. 2 camshaft are positioned as shown in the illustration.

    2. B006XQON01

      Uniformly loosen and remove the 9 bolts in several steps in the order shown in the illustration.

    3. B006ZV8N01

      Uniformly loosen and remove the 15 bolts in several steps in the order shown in the illustration.

      Note

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

    4. B006YX8

      Remove the fuel pump lifter housing from the camshaft housing sub-assembly.

    5. B006YZE

      Remove the 5 camshaft bearing caps from the camshaft housing sub-assembly.

    6. B0071MK

      Remove the 2 oil control valve filters from the 2 camshaft bearing caps.

  50. REMOVE CAMSHAFT


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

  51. REMOVE NO. 2 CAMSHAFT


    1. Remove the No. 2 camshaft from the camshaft housing sub-assembly.

  52. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B006YSGC01
      *a Protective Tape

      Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver with its tip wrapped with protective tape.

      Note

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

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


    1. B006ZGGC01
      *a Pin
      *b Plunger
      B006ZY0 Push

      While pushing down the No. 3 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the hole to secure the No. 3 chain tensioner assembly.

    2. B0070MRC01
      *a Hold
      B006Z38 Turn

      Using a wrench to hold the hexagonal portion of No. 3 camshaft sub-assembly, loosen the camshaft timing gear bolt of the camshaft timing gear assembly.

      Note


      • Be careful not to damage the No. 3 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with wrench.

      • Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.

      • If the camshaft timing gear bolt has been struck or dropped, replace it.

    3. B006XL4C01
      *a Hold
      B006Z38 Turn

      Using a wrench to hold the hexagonal portion of No. 4 camshaft sub-assembly, loosen the camshaft timing gear bolt of the camshaft timing exhaust gear assembly.

      Note


      • Be careful not to damage the No. 4 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with wrench.

      • Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.

      • If the camshaft timing gear bolt has been struck or dropped, replace it.

    4. Remove the 2 camshaft timing gear bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly together with the No. 2 chain sub-assembly.

  54. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B006ZK9

      Remove the bolt and No. 3 chain tensioner assembly from the camshaft housing sub-assembly LH.

  55. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. B00708QC01
      *a Straight Pin
      *b Front View

      Check that the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly are positioned as shown in the illustration.

    2. B00703EN01

      Uniformly loosen and remove the 8 bolts in several steps in the order shown in the illustration.

    3. B006YWQN01

      Uniformly loosen and remove the 15 bolts in several steps in the order shown in the illustration.

      Note

      Make sure that the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly remain level while uniformly loosening the bolts.

    4. B006YN9

      Remove the 5 camshaft bearing caps from the camshaft housing sub-assembly LH.

    5. B006YNW

      Remove the 2 oil control valve filters from the 2 camshaft bearing caps.

  56. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY


    1. Remove the No. 3 camshaft sub-assembly from the camshaft housing sub-assembly LH.

  57. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY


    1. Remove the No. 4 camshaft sub-assembly from the camshaft housing sub-assembly LH.

  58. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. B006ZYGC01
      *a Protective Tape

      Remove the camshaft housing sub-assembly LH by prying between the cylinder head LH and camshaft housing sub-assembly LH with a screwdriver with its tip wrapped with protective tape.

      Note

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

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


    1. B006ZSL

      Remove the 24 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly and cylinder head LH.

      Tech Tips

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

  60. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. B0070XL

      Remove the 24 valve lash adjuster assemblies from the cylinder head sub-assembly and cylinder head LH.

      Tech Tips

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

  61. REMOVE VALVE STEM CAP


    1. B006ZM2

      Remove the 24 valve stem caps from the cylinder head sub-assembly and cylinder head LH.

      Tech Tips

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

  62. REMOVE SENSOR WIRE


    1. B006XUW

      Remove the 3 bolts and sensor wire from the cylinder head LH and cylinder block sub-assembly.

  63. REMOVE REAR ENGINE OIL SEAL RETAINER


    1. B0070JT

      Remove the 6 bolts from the rear engine oil seal retainer.

    2. B006XUSC01
      *a Protective Tape
      B006Z38 Pry

      Using a screwdriver with its tip wrapped with protective tape, pry out the rear engine oil seal retainer.

      Note

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

  64. REMOVE REAR ENGINE OIL SEAL


    1. B00704RC01
      *a Protective Tape
      *b Wooden Block

      Place the rear engine oil seal retainer on wooden blocks.

    2. Using a hammer and a screwdriver with its tip wrapped with protective tape, tap out the rear engine oil seal.

      Note

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

  65. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B00701JN01

      Using a 10 mm bi-hexagon socket wrench, uniformly loosen the 8 cylinder head set bolts in the order shown in the illustration. Remove the 8 cylinder head set bolts and 8 cylinder head set plate washers.

      Note


      • Be careful not to drop the cylinder head set 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.

      Tech Tips

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

    2. Remove the cylinder head sub-assembly from the cylinder block sub-assembly.

  66. REMOVE CYLINDER HEAD GASKET

    Click here

  67. REMOVE CYLINDER HEAD LH


    1. B006YV8N01

      Uniformly loosen and remove the 2 bolts in several steps in the order shown in the illustration.

    2. B006XLVN01

      Using a 10 mm bi-hexagon socket wrench, uniformly loosen the 8 cylinder head set bolts in the order shown in the illustration. Remove the 8 cylinder head set bolts and 8 cylinder head set plate washers.

      Note


      • Be careful not to drop the cylinder head set plate washers into the cylinder head LH.

      • Warpage or cracking of the cylinder head LH may result from removing the cylinder head set bolts in the incorrect order.

      Tech Tips

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

    3. Remove the cylinder head LH from the cylinder block sub-assembly.

  68. REMOVE NO. 2 CYLINDER HEAD GASKET

    Click here

  69. REMOVE WATER INLET PIPE


    1. B004O2O

      Remove the 2 bolts and water inlet pipe from the cylinder block sub-assembly.

  70. REMOVE STRAIGHT PIN

    Note

    It is not necessary to remove the straight pins unless they are being replaced.

  71. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

    Note

    It is not necessary to remove the camshaft bearing cap setting ring pins unless they are being replaced.

  72. REMOVE STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.