ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP ASSEMBLY


    1. Remove the oil filler cap assembly from the oil filler cap housing.

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

  2. REMOVE OIL FILLER CAP HOUSING


    1. B000W4F

      Remove the 2 bolts, oil filler cap housing and oil filler cap housing gasket.

  3. REMOVE SPARK PLUG

    Click here

  4. REMOVE OIL PAN DRAIN PLUG


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

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

    Click here

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

    Click here

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

    Click here

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

    Click here

  9. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  10. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  11. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY LH

    Click here

  12. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH

    Click here

  13. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. B000Z0DC04
      *a for Bank 1
      *b for Bank 2

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

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

  14. REMOVE CAMSHAFT TIMING CONTROL MOTOR WITH EDU ASSEMBLY LH

    Click here

  15. REMOVE CAMSHAFT TIMING CONTROL MOTOR WITH EDU ASSEMBLY RH

    Click here

  16. REMOVE FRONT WATER BY-PASS JOINT


    1. B000YWD

      Remove the 4 nuts, front water by-pass joint and 2 gaskets.

  17. REMOVE OIL FILTER CAP ASSEMBLY


    1. B000WYBC02
      *a Oil Filter Cap Assembly Rib

      Using SST, loosen the oil filter cap assembly 4 turns, align the cap ribs vertically, and drain the remaining engine oil from the oil filter cap assembly.

      SST
      09228-06502

      Tech Tips

      Set a container below the oil filter cap assembly before loosening the oil filter cap assembly.

    2. Remove the oil filter cap assembly.

    3. B000Y4FC03
      *1 Oil Filter Element
      *2 Oil Filter Cap Assembly
      *3 O-ring

      Remove the oil filter element and O-ring from the oil filter cap assembly.

      Note

      Do not use any tools to remove the O-ring in order to prevent the oil filter cap assembly from being damaged. Be sure to remove it by hand.

  18. REMOVE OIL COOLER ASSEMBLY

    Click here

  19. REMOVE OIL FILTER BRACKET


    1. B000XTV

      Remove the 2 bolts and oil filter bracket stay.

    2. B000VBGC01
      B000XM7 Bolt
      B000TT4 Nut

      Remove the 2 bolts, 2 nuts and oil filter bracket.

    3. Remove the 2 gaskets from the timing chain cover assembly.

  20. REMOVE CRANKSHAFT PULLEY ASSEMBLY

    Click here

  21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. B000U4K

      Remove the fuel pump spacer gasket.

    2. Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly LH and cylinder head cover gasket LH.

      Tech Tips

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

    3. B000Z2JC02
      B000XM7 Oil Hole Gasket
      B000TT4 O-ring

      Remove the 2 oil hole gaskets and 2 O-rings from the camshaft bearing caps.

  22. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B000UUM

      Remove the fuel pump spacer gasket.

    2. Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.

      Tech Tips

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

    3. B000VKEC02
      B000XM7 Oil Hole Gasket
      B000TT4 O-ring

      Remove the 2 oil hole gaskets and 2 O-rings from the camshaft bearing caps.

  23. REMOVE SPARK PLUG TUBE GASKET


    1. B000WKOC02
      *a Protective Tape

      Using a screwdriver, pry out the 8 spark plug tube gaskets from each cylinder head sub-assembly and cylinder head LH.

      Tech Tips

      Tape the screwdriver tip before use.

  24. REMOVE OIL CONTROL VALVE FILTER LH


    1. B000UK5C06
      *1 Oil Control Valve Filter LH
      *2 Cylinder Head Cover Spacer LH
      *a Gasket

      Remove the 2 bolts, cylinder head cover spacer LH and gasket.

    2. Remove the oil control valve filter LH from the cylinder head cover spacer LH.

  25. REMOVE OIL CONTROL VALVE FILTER RH


    1. B000YCSC05
      *1 Oil Control Valve Filter RH
      *2 Cylinder Head Cover Spacer RH
      *a Gasket

      Remove the 2 bolts, cylinder head cover spacer RH and gasket.

    2. Remove the oil control valve filter RH from the cylinder head cover spacer RH.

  26. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. B000Z6PC02
      B000XM7 6 mm Hexagon Bolt
      B000TT4 Bolt

      Remove the bolt, 6 mm hexagon bolt and V-ribbed belt tensioner assembly.

  27. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. B000TZN

      Remove the 5 bolts, engine water pump assembly and water pump gasket from the timing chain cover assembly.

  28. REMOVE TIMING CHAIN COVER ASSEMBLY

    Click here

  29. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL

    Click here

  30. REMOVE INLET WATER PIPE


    1. B000Z1A

      Remove the inlet water pipe.

    2. Remove the 2 O-rings from the inlet water pipe.

  31. REMOVE NO. 1 OIL PIPE

    Click here

  32. REMOVE NO. 2 OIL PIPE

    Click here

  33. REMOVE NO. 3 OIL PIPE

    Click here

  34. REMOVE SCAVENGING PUMP ASSEMBLY

    Click here

  35. SET NO. 1 CYLINDER TO TDC / COMPRESSION


    1. Temporarily tighten the crankshaft pulley set bolt.

    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear assembly and camshaft timing gears are as shown in the illustration.

      B000VS1C05
      *a Timing Mark *b Timing Mark Position
      *c Knock Pin Position *d Approximately 2°
      *e Approximately 45° *f Approximately 16°
      *g Upward *h Approximately 20°
      *i Approximately 33° *j Crankshaft Timing Gear Key

      Tech Tips

      If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

  36. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH (for Bank 1)


    1. B000X7QC01
      *a Stopper Plate
      *b Plunger
      *c Pin

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

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

    3. B000U0C

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

    4. Remove the chain tensioner gasket.

  37. REMOVE CHAIN TENSIONER SLIPPER LH (for Bank 1)


    1. B000Z21

      Remove the chain tensioner slipper LH.

  38. REMOVE CHAIN VIBRATION DAMPER LH (for Bank 1)


    1. B000YWA

      Remove the 2 bolts and chain vibration damper LH.

  39. REMOVE CHAIN SUB-ASSEMBLY (for Bank 1)


    1. B000XAYC01
      *a Pin
      *b Plunger
      *c Push

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

    2. B000VBHC02
      *a Hold
      *b Turn

      Using a wrench, hold the hexagonal portion of the No. 3 camshaft sub-assembly and loosen the bolt with a 12 mm hexagon socket wrench.

      Note


      • Be careful not to damage the cylinder head with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

    3. B000W36C01
      *a Hold
      *b Turn

      Using a wrench, hold the hexagonal portion of the No. 4 camshaft sub-assembly and loosen the bolt with a wrench.

      Note

      Be careful not to damage the cylinder head with the wrench.

    4. Remove the 2 bolts. Then with the chain sub-assembly and No. 2 chain sub-assembly still attached to the gears, remove the camshaft timing intake gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket LH.

    5. Remove the chain sub-assembly and No. 2 chain sub-assembly from the gears.

  40. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B000Y21

      Remove the 2 bolts and No. 3 chain tensioner assembly.

  41. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH (for Bank 2)


    1. B000VFAC01
      *a Plunger
      *b Stopper Plate
      *c Pin

      Turn the stopper plate clockwise to release the lock, and fully push the plunger into the tensioner.

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

    3. B000V0B

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

  42. REMOVE CHAIN TENSIONER SLIPPER RH (for Bank 2)


    1. B000WLT

      Remove the chain tensioner slipper RH.

  43. REMOVE CHAIN VIBRATION DAMPER RH (for Bank 2)


    1. B000YLB

      Remove the 2 bolts and chain vibration damper RH.

  44. REMOVE CHAIN SUB-ASSEMBLY (for Bank 2)


    1. B000ULMC01
      *a Push
      *b Plunger
      *c Pin

      While pushing up the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to secure it in place.

    2. B000Y7WC01
      *a Hold
      *b Turn

      Using a wrench, hold the hexagonal portion of the camshaft and loosen the bolt with a 12 mm hexagon socket wrench.

      Note


      • Be careful not to damage the cylinder head with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

    3. B000VXIC01
      *a Hold
      *b Turn

      Using a wrench, hold the hexagonal portion of the No. 2 camshaft and loosen the bolt with a wrench.

      Note

      Be careful not to damage the cylinder head with the wrench.

    4. Remove the 2 bolts. Then with the chain sub-assembly and No. 2 chain sub-assembly still attached to the gears, remove the camshaft timing intake gear assembly, camshaft timing exhaust gear assembly and crankshaft timing gear.

    5. Remove the chain sub-assembly and No. 2 chain sub-assembly from the gears.

  45. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B000UBN

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

  46. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. B000U9A

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

  47. REMOVE OIL REFLECTOR PLATE LH


    1. B000VFV

      Remove the 2 bolts and oil reflector plate LH from the cylinder head LH.

  48. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

    Click here

  49. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

    Click here

  50. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

    Click here

  51. REMOVE OIL REFLECTOR PLATE RH


    1. B000W2Y

      Remove the 2 bolts and oil reflector plate RH from the cylinder head sub-assembly.

  52. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

    Click here

  53. REMOVE CAMSHAFT

    Click here

  54. REMOVE NO. 2 CAMSHAFT

    Click here

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


    1. B000U2KC01
      *1 Valve Adjusting Shim
      *2 Cylinder Head Valve Rocker Arm Pivot

      Remove the 32 No. 1 valve rocker arm sub-assemblies from the cylinder head LH and cylinder head sub-assembly.

      Tech Tips

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

  56. REMOVE CYLINDER HEAD VALVE ROCKER ARM PIVOT LH


    1. Remove the 16 cylinder head valve rocker arm pivots LH from the cylinder head LH.

  57. REMOVE CYLINDER HEAD VALVE ROCKER ARM PIVOT RH


    1. Remove the 16 cylinder head valve rocker arm pivots RH from the cylinder head sub-assembly.

  58. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    Click here

  59. REMOVE CYLINDER HEAD GASKET

    Click here

  60. REMOVE CYLINDER HEAD LH

    Click here

  61. REMOVE NO. 2 CYLINDER HEAD GASKET

    Click here

  62. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. B000V71

      Remove the 2 cylinder block water jacket spacers from the cylinder block sub-assembly.

      Note

      Be sure to remove the cylinder block water jacket spacers. Otherwise, they may fall out and be damaged when the cylinder block is inverted.

  63. REMOVE HEAT EXCHANGER ASSEMBLY


    1. B000VBM

      Remove the bolt.

    2. B000XOVC02
      B000XM7 Bolt
      B000TT4 Nut

      Remove the 11 bolts and 2 nuts.

    3. B000U40C03
      *a Protective Tape

      Remove the heat exchanger assembly by prying between the heat exchanger assembly and cylinder block sub-assembly with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

  64. REMOVE PCV PIPE GASKET


    1. B000YM1C02
      *a Protective Tape

      Using a screwdriver, pry out the PCV pipe gasket.

      Tech Tips

      Tape the screwdriver tip before use.

  65. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. B000ULGC02
      B000XM7 Bolt
      B000TT4 Nut

      Remove the 15 bolts and 2 nuts.

    2. B000Y9ZC04
      *1 Oil Pan Seal Cutter

      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 pan sub-assembly and No. 2 oil pan sub-assembly.

  66. REMOVE OIL PAN SUB-ASSEMBLY


    1. B000X1NC03
      B000XM7 Bolt
      B000TT4 Nut

      Remove the 14 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. B000US2C05
      *a for Bank 1 Side
      *b for Bank 2 Side

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  67. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. B000TV5

      Remove the 8 bolts and No. 1 oil pan baffle plate.

  68. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B000ZC5

      Remove the 2 bolts, oil strainer sub-assembly and O-ring.

  69. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. B000Z96

      Remove the 6 bolts.

    2. B000U38C11
      *a Protective Tape

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

      Note

      Be careful not to damage the engine rear oil seal retainer and cylinder block sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  70. REMOVE ENGINE REAR OIL SEAL


    1. B000VVIC07
      *a Wooden Block
      *b Protective Tape

      Place the engine rear oil seal retainer on wooden blocks.

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

  71. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY


    1. B000U47

      Remove the bolt and oil drain pipe sub-assembly.

    2. Remove the O-ring from the oil drain pipe sub-assembly.