ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE SPARK PLUG

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  2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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  3. REMOVE NO. 1 FUEL TUBE SUB-ASSEMBLY

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  4. REMOVE PCV VALVE

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

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

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

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

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

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

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

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

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  13. REMOVE CRANKSHAFT POSITION SENSOR

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  14. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. B004W66C01
      *a RH Side
      *b LH Side

      Remove the water drain cock plug from the water drain cock.

    2. Remove the water drain cock from the cylinder block.

    3. Remove the taper screw plug from the cylinder block.

  15. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

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

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  17. REMOVE OIL FILTER CAP ASSEMBLY

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  18. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

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  19. REMOVE CRANKSHAFT PULLEY

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  20. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY


    1. B004U6Y

      Remove the 2 bolts, nut, water inlet with thermostat sub-assembly.

    2. Remove the gasket from the water inlet with thermostat sub-assembly.

  21. REMOVE WATER OUTLET


    1. B004V9I

      Remove the 2 bolts and the water outlet.

    2. B004XEO

      Remove the O-ring.

  22. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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  23. REMOVE REAR WATER BY-PASS JOINT


    1. B004VEV

      Remove the 4 bolts, 2 nuts and rear water by-pass joint.

    2. Remove the 2 gaskets from the rear water by-pass joint.

    3. B004T2C

      Remove the O-ring from the No. 1 water outlet pipe.

  24. REMOVE FUEL PUMP SPACER GASKET


    1. Remove the fuel pump spacer gasket from the cylinder head cover sub-assembly.

  25. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  26. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

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  27. REMOVE SPARK PLUG TUBE GASKET


    1. B004RR6

      Remove the 6 spark plug tube gaskets.

      Tech Tips

      Be careful not to damage the gasket when removing it as the removed gasket needs to be used when installing a new one.

  28. REMOVE OIL PAN DRAIN PLUG


    1. Remove the oil pan drain plug and gasket.

  29. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

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  30. REMOVE ENGINE OIL LEVEL SENSOR

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  31. REMOVE OIL LEVEL SENSOR BRACKET

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  32. REMOVE OIL PAN SUB-ASSEMBLY

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  33. REMOVE OIL STRAINER SUB-ASSEMBLY

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  34. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. B004VX8

      for 2WD:


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

    2. B004VX8

      for AWD:


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

  35. REMOVE REAR ENGINE OIL SEAL RETAINER


    1. B004SBP

      Remove the 6 bolts.

    2. B004RJNC02
      B004SZX Pry

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  36. REMOVE REAR ENGINE OIL SEAL


    1. B004UVZC02
      *a Wooden Block
      *b Protective Tape

      Place the rear engine oil seal retainer on wooden blocks.

      Note

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

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

      Tech Tips

      Tape the screwdriver tip before use.

  37. REMOVE TIMING CHAIN COVER ASSEMBLY

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  38. REMOVE ENGINE WATER PUMP ASSEMBLY

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  39. REMOVE TIMING CHAIN CASE OIL SEAL

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  40. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the pulley set bolt.

    2. B004TNQC01
      *1 Crankshaft Pulley Set Key
      *a Center Mark

      Set the crankshaft pulley set key to the RH block bore center mark (TDC/compression).

    3. B004YNSC01
      *a Timing Mark

      Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.

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

  41. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B004RF4C02
      *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 pin of 1.27 mm (0.0500 in.) diameter into the stopper plate's hole.

    3. B004Y44

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

  42. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  43. REMOVE CHAIN SUB-ASSEMBLY


    1. B004V1DC01
      *a Timing Mark
      *b Center Line

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

    2. Remove the pulley set bolt.

    3. B004W03

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

    4. B004YBVC01
      *A for Bank 1

      Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the banks.

    5. Remove the chain sub-assembly.

  44. REMOVE IDLE SPROCKET ASSEMBLY


    1. B004RDK

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

  45. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B004XRX

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

  46. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. B004U1Z

      Remove the 2 No. 2 chain vibration dampers.

  47. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET


    1. B004S66

      Remove the crankshaft timing gear or sprocket from the crankshaft.

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

  48. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

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  49. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

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  50. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

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  51. REMOVE FUEL PUMP LIFTER HOUSING

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  52. REMOVE CAMSHAFT

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  53. REMOVE NO. 2 CAMSHAFT

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  54. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

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  55. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

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  56. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

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  57. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

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  58. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

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  59. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

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  60. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

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  61. REMOVE OIL CONTROL VALVE FILTER LH


    1. B004THLC03
      *1 Oil Control Valve Filter LH

      Remove the oil control valve filter LH from the camshaft bearing cap.

  62. REMOVE OIL CONTROL VALVE FILTER RH


    1. Remove the oil control valve filter RH from the camshaft bearing cap.

  63. REMOVE CAMSHAFT BEARING CAP OIL HOLE GASKET


    1. B004XGMC03
      *1 Camshaft Bearing Cap Oil Hole Gasket

      Remove the camshaft bearing cap oil hole gasket from the No. 6 camshaft bearing cap.

    2. B004TVPC03
      *1 Camshaft Bearing Cap Oil Hole Gasket

      Remove the camshaft bearing cap oil hole gasket from the No. 7 camshaft bearing cap.

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

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  65. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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  66. REMOVE VALVE STEM CAP

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  67. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  68. REMOVE CYLINDER HEAD GASKET

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  69. REMOVE CYLINDER HEAD LH

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  70. REMOVE NO. 2 CYLINDER HEAD GASKET

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  71. REMOVE SENSOR WIRE


    1. B004V3E

      Detach the clamp and remove the No. 5 engine wire.

  72. REMOVE KNOCK CONTROL SENSOR

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  73. REMOVE NO. 1 WATER OUTLET PIPE


    1. B004VNC

      Remove the 2 bolts and No. 1 water outlet pipe.

  74. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    B004X5T

    1. Remove the 2 water jacket spacers from the cylinder block.

      Note

      Be sure to remove the water jacket spacers. If not, they may fall and become damaged when the cylinder block is inverted.

  75. REMOVE STRAIGHT PIN

    Note

    It is not necessary to remove a No. 1 straight pin unless it is being replaced.

  76. REMOVE RING PIN

    Note

    It is not necessary to remove a ring pin unless it is being replaced.