ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


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

  2. REMOVE SPARK PLUG


    1. Remove the spark plugs.

  3. REMOVE OIL PAN DRAIN PLUG


    1. A017B5U

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

  4. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A017FBY

      Remove the ventilation valve sub-assembly.

  5. REMOVE CAMSHAFT POSITION SENSOR


    1. A017B7IE04

      Remove the 4 bolts and 4 camshaft position sensors.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A017EVCE06

      Remove the 4 bolts and 4 camshaft timing oil control valves.

  7. REMOVE CRANKSHAFT POSITION SENSOR


    1. A017CZI

      Remove the bolt and crankshaft position sensor.

  8. REMOVE NO. 1 OIL PIPE


    1. A017BIAE01

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

    2. Remove the oil control valve filter LH and gaskets.

  9. REMOVE OIL PIPE


    1. A017DWSE16

      Remove the bolt.

    2. Remove the 2 oil pipe unions and oil pipe.

    3. Remove the oil control valve filter RH and gaskets.

  10. REMOVE TAPER SCREW PLUG

    Tech Tips

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


    1. A017FHP

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

  11. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A017EDPE04

      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 ELEMENT


    1. A017DWH

      Remove the drain plug.

      Note

      Do not remove the O-ring from the oil filter cap sub-assembly.

    2. A017D8KE01

      Connect the hose to the pipe.

    3. Insert the pipe with hose into the oil filter cap sub-assembly.

    4. Make sure that the oil is completely drained and remove the pipe and O-ring.

    5. A017EKYE01

      Using SST, remove the oil filter cap sub-assembly.

      SST
      09228-06501
    6. A017DLFE06

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

      Note

      Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.

  13. REMOVE CRANKSHAFT PULLEY


    1. A017DNME02

      Using SST, loosen the crankshaft pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A017C87E02

      Using SST, remove the crankshaft pulley bolt and crankshaft pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

  14. REMOVE OIL COOLER ASSEMBLY


    1. A017CAH

      Remove the bolt, 2 clamps and 4 clips, and disconnect the 2 water by-pass hoses.

    2. A017E70

      Remove the union bolt, oil cooler assembly, and O-ring.

  15. REMOVE NO. 1 OIL COOLER BRACKET


    1. A017D8G

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

    2. A017DSWE03

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

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

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

  16. REMOVE NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the No. 1 engine oil level dipstick guide.

    2. A017EP2

      Remove the O-ring.

  17. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A017FNW

      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. A017ECE

      Remove the 2 nuts, water inlet and thermostat.

    2. Remove the gasket.

    3. Remove the 2 stud bolts.

    4. Separate the No. 1 water by-pass hose from the water inlet housing.

    5. A017F72E01

      Remove the drain cock plug.

    6. Remove the drain cock assembly.

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

    8. A017E0A

      Remove the 2 O-rings.

  19. REMOVE WATER OUTLET


    1. A017B9GE01

      Remove the 2 bolts, 4 nuts and water outlet.

    2. A017DIQ

      Remove the 2 gaskets and O-ring.

  20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)


    1. A017CFI

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

    2. A017F2Q

      Remove the 3 gaskets.

  21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)


    1. A017BDFE02

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

    2. A017FVT

      Remove the 3 gaskets.

  22. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A017B87E01

      Remove the 16 bolts and 2 nuts.

    2. A017BN3

      Insert the blade of an oil pan seal cutter between the oil pans. 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.

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

  23. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A017DJH

      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. A017FQ1E01

      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. A017FULE01

      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. A017D6L

      Remove the 2 O-rings.

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

  25. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A017ETB

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

  26. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A017G64

      Remove the 6 bolts.

    2. A017FT8E03

      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. A017DPRE12

      Place the engine rear oil seal retainer on wooden blocks.

      Note

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

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

      Tech Tips

      Tape the screwdriver tip before use.

  28. REMOVE WATER PUMP ASSEMBLY


    1. A017G21

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

  29. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A017G1VE01

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

    2. A017EMOE02

      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, chain cover plate and chain cover plate gasket.

    4. A017CE0E01

      Remove the gasket.

  30. REMOVE TIMING CHAIN CASE OIL SEAL


    1. A017BHBE01

      Using a screwdriver, pry out the timing chain case oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  31. SET NO. 1 CYLINDER TO TDC / COMPRESSION


    1. Temporarily tighten the pulley set bolt.

    2. A017BSAE12

      Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC / compression).

    3. A017FZJE10

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

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

  32. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A017G4QE13

      Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

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

    3. A017FY1

      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. A017CVGE02

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

    2. Remove the pulley set bolt.

    3. A017D6Y

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

    4. A017FNHE05

      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 sub-assembly between the banks.

    5. Remove the chain sub-assembly.

  35. REMOVE IDLE SPROCKET ASSEMBLY


    1. A017BLF

      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. A017C4N

      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. A017FLA

      Remove the crankshaft timing sprocket from the crankshaft.

    2. Remove the 2 keys from the crankshaft.

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


    1. A017EISE03

      While raising the No. 2 chain tensioner assembly, insert a pin of 1.0 mm diameter (0.039 in.) into the hole to fix the No. 2 chain tensioner assembly.

    2. A017DZAE01

      Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.

      Note


      • Be careful not to damage the cylinder head sub-assembly RH with the wrench.

      • Do not disassemble the camshaft timing gear assemblies.

    3. Remove the No. 2 chain sub-assembly.

  40. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A017EJ9

      Remove the bolt and No. 2 chain tensioner assembly.

  41. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A017D7TE01

      Check that the camshafts are positioned as shown in the illustration.

    2. A017CEQE03

      Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration.

    3. A017BN4E01

      Uniformly loosen and remove the 12 bearing cap bolts in several steps in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshafts level.

    4. Remove the 5 camshaft bearing caps.

  42. REMOVE CAMSHAFT


    1. Remove the camshaft.

  43. REMOVE NO. 2 CAMSHAFT


    1. Remove the No. 2 camshaft.

  44. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A017DURE01

      Remove the camshaft housing sub-assembly RH by prying between the cylinder head sub-assembly RH and camshaft housing sub-assembly RH with a screwdriver.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. A017F5RE01

      While pushing down the No. 3 chain tensioner assembly, insert a pin of 1.0 mm diameter (0.039 in.) into the hole to fix the No. 3 chain tensioner assembly.

    2. A017EQQE01

      Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.

      Note


      • Be careful not to damage the cylinder head sub-assembly LH with the wrench.

      • Do not disassemble the camshaft timing gear assemblies.

    3. Remove the No. 2 chain sub-assembly.

  46. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A017CF9

      Remove the bolt and No. 3 chain tensioner assembly.

  47. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A017CCRE01

      Check that the camshafts are positioned as shown in the illustration.

    2. A017F42E03

      Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration.

    3. A017FNRE01

      Uniformly loosen and remove the 13 bearing cap bolts in several steps and in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshafts level.

    4. Remove the 5 camshaft bearing caps.

  48. REMOVE NO. 3 CAMSHAFT


    1. Remove the No. 3 camshaft.

  49. REMOVE NO. 4 CAMSHAFT


    1. Remove the No. 4 camshaft.

  50. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A017BDME01

      Remove the camshaft housing sub-assembly LH by prying between the cylinder head sub-assembly LH and camshaft housing sub-assembly LH with a screwdriver.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. Remove the 24 No. 1 valve rocker arm sub-assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  52. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 24 valve lash adjuster assemblies from the 2 cylinder head sub-assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  53. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH


    1. A017FOYE01

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

      Note


      • Be careful not to drop plate washers into the cylinder head sub-assembly RH.

      • Cylinder head warpage or cracking could result from removing bolts in an incorrect order.

      Tech Tips

      Be sure to keep separate the removed parts for each installation position.

    2. Remove the cylinder head sub-assembly RH and cylinder head gasket.

  54. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. A017D6GE01

      Uniformly loosen and remove the 2 cylinder head set bolts in several steps and in the sequence shown in the illustration.

    2. A017DQUE01

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

      Note


      • Be careful not to drop plate washers into the cylinder head sub-assembly LH.

      • Cylinder head warpage or cracking could result from removing bolts in an incorrect order.

      Tech Tips

      Be sure to keep separate the removed parts for each installation position.

    3. Remove the cylinder head sub-assembly LH and No. 2 cylinder head gasket.

  55. REMOVE WATER INLET PIPE


    1. Remove 2 clamps and separate the No. 1 water by-pass hose.

    2. A017DCT

      Remove the 2 bolts and water inlet pipe.