ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  2. REMOVE OIL FILLER CAP HOUSING


    1. A01GJ96

      Remove the 2 bolts, filler cap housing and gasket.

  3. REMOVE SPARK PLUG


    1. A01GLTF

      Using a 16 mm plug wrench, remove the 8 spark plugs.

  4. REMOVE VVT SENSOR


    1. A01GKUV

      for Bank 1:

      Remove the 2 bolts and 2 VVT sensors.

    2. A01GLPJ

      for Bank 2:

      Remove the 2 bolts and 2 VVT sensors.

  5. REMOVE CAMSHAFT POSITION SENSOR


    1. A01GN1A

      Remove the bolt and camshaft position sensor.

  6. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01GHUM

      Remove the bolt and crankshaft position sensor.

  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01GNMQ

      for Bank 1:

      Remove the bolt and oil control valve.

    2. A01GMYQ

      for Bank 2:

      Remove the bolt and oil control valve.

  8. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. Remove the 2 water drain cock plugs from the water drain cocks.

      A01GKH8E01

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

  9. REMOVE CAMSHAFT TIMING CONTROL WITH EDU MOTOR ASSEMBLY LH


    1. A01GIVB

      Disconnect the 2 camshaft timing control with EDU motor assembly LH connectors and engine wire clamp.

    2. A01GHPG

      Remove the 3 bolts and camshaft timing control with EDU motor assembly LH.

      Note

      Do not allow foreign matter to contact the oil seal face of the camshaft timing control with EDU motor assembly LH (connecting surface with timing chain cover).

    3. Remove the O-ring from the timing chain cover.

  10. REMOVE CAMSHAFT TIMING CONTROL WITH EDU MOTOR ASSEMBLY RH


    1. A01GML7

      Disconnect the 2 camshaft timing control with EDU motor assembly RH connectors.

    2. Remove the bolt and engine wire bracket.

    3. A01GIJS

      Remove the 3 bolts and camshaft timing control with EDU motor assembly RH.

      Note

      Do not allow foreign matter to contact the oil seal face of the camshaft timing control with EDU motor assembly RH (connecting surface with timing chain cover).

    4. Remove the O-ring from the timing chain cover.

  11. REMOVE OIL FILTER ELEMENT (for 2WD)


    1. A01GJULE11
      Text in Illustration
      *1 Pipe
      *2 Hose

      Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

    2. A01GKIK

      Remove the oil filter drain plug.

    3. A01GM41E02
      Text in Illustration
      *1 Oil Filter Cap
      *2 Valve
      *3 Pipe
      *4 O-Ring
      *5 Hose

      Install the pipe to the oil filter cap.

      Note

      If the O-ring is removed with the drain plug, install the O-ring together with the pipe.

      Tech Tips

      Use a container to catch the draining oil.

    4. A01GNWA

      Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring as shown in the illustration.

    5. A01GII4E02
      Text in Illustration
      *1 Oil Filter Bracket Clip

      Using SST, remove the oil filter cap.

      SST
      09228-06501

      Note

      Do not remove the oil filter bracket clip.

    6. A01GMCZE03
      Text in Illustration
      *1 O-Ring

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

      Note

      Be sure to remove the O-ring (for the cap) by hand, without using any tools, to prevent damage to the groove.

  12. REMOVE OIL FILTER ELEMENT (for AWD)


    1. A01GJULE11
      Text in Illustration
      *1 Pipe
      *2 Hose

      Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

    2. A01GNHB

      Remove the oil filter drain plug.

      Tech Tips

      Use a container to catch the draining oil.

    3. A01GM81E02
      Text in Illustration
      *1 Oil Filter Cap
      *2 Valve
      *3 Pipe
      *4 O-Ring
      *5 Hose

      Install the pipe to the oil filter cap.

      Note

      If the O-ring is removed with the drain plug, install the O-ring together with the pipe.

    4. A01GMFO

      Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring as shown in the illustration.

    5. A01GMPVE02
      Text in Illustration
      *1 Oil Filter Bracket Clip

      Using SST, remove the oil filter cap.

      SST
      09228-06501

      Note

      Do not remove the oil filter bracket clip.

    6. A01GMCZE03
      Text in Illustration
      *1 O-Ring

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

      Note

      Be sure to remove the O-ring (for the cap) by hand, without using any tools, to prevent damage to the groove.

  13. REMOVE OIL FILTER BRACKET (for 2WD)


    1. A01GLHS

      Remove the 3 bolts, filter bracket and 2 gaskets.

  14. REMOVE OIL FILTER BRACKET (for AWD)


    1. A01GL3X

      Remove the 3 bolts, filter bracket and 2 gaskets.

  15. REMOVE FRONT WATER BY-PASS JOINT


    1. A01GHO4

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

  16. REMOVE SPARK PLUG TUBE GASKET


    1. A01GMX7E01

      Using a screwdriver, pry out the 8 plug tube gaskets.

      Tech Tips

      Tape the screwdriver tip before use.

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01GKDQE03

      Remove the fuel pump spacer gasket.

    2. Remove the 15 bolts, 2 seal washers, cylinder head cover and gasket.

      Tech Tips

      Make sure the removed parts are returned to the same places they were removed from.

    3. A01GILM

      Remove the 4 gaskets and 2 O-rings from the camshaft bearing caps (No. 2, No. 3, No. 7).

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A01GHZKE03

      Remove the fuel pump spacer gasket.

    2. Remove the 15 bolts, 2 seal washers, cylinder head cover and gasket.

      Tech Tips

      Make sure the removed parts are returned to the same places they were removed from.

    3. A01GM0S

      Remove the 4 gaskets and 2 O-rings from the camshaft bearing caps (No. 1, No. 3, No. 6).

  19. REMOVE OIL CONTROL VALVE FILTER


    1. for Bank 1:


      1. A01GNJ7E01

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

    2. for Bank 2:


      1. A01GNAFE01

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

  20. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01GM9G

      Remove the standard bolt, 6 mm hexagon wrench bolt and belt tensioner.

  21. REMOVE CRANKSHAFT PULLEY


    1. A01GMVCE01

      Using SST, loosen the crankshaft pulley set bolt.

      SST
      09213-54015   ( 90119-08216 )
      09330-00021
    2. A01GN76E01

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05011 )

  22. REMOVE WATER PUMP ASSEMBLY


    1. A01GL1X

      Remove the 9 bolts, engine water pump and gasket.

  23. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01GL8Q

      Remove the 2 plugs and 2 gaskets.

    2. A01GNFEE01

      Remove the 30 bolts and nut shown in the illustration.

    3. A01GK19

      Remove the timing chain cover by prying between the timing chain cover and cylinder head and cylinder block with a screwdriver as shown in the illustration.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

    4. A01GII0

      Remove the oil pump gasket from the cylinder block.

    5. A01GNMX

      Remove the O-ring from the cylinder block.

  24. REMOVE TIMING CHAIN CASE OIL SEAL


    1. A01GNDT

      Remove the timing chain case oil seal with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

      Do not damage the surface of the timing chain case oil seal press fit hole and crankshaft.

  25. REMOVE WATER INLET PIPE


    1. A01GIAM

      Remove the water inlet pipe.

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

  26. SET NO. 1 CYLINDER TO TDC / COMPRESSION


    1. Temporarily install the pulley set bolt.

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

      Tech Tips

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

      A01GMUJE01

  27. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1)


    1. A01GJTQE01

      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 hole.

    3. A01GI31

      Remove the 2 bolts, chain tensioner and gasket.

  28. REMOVE CHAIN TENSIONER SLIPPER (for Bank 1)

  29. REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 1)


    1. A01GJ1V

      Remove the 2 bolts and chain vibration damper.

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


    1. A01GL0YE01

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

    2. A01GM72E01

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt with a 12 mm hexagon wrench.

      Note


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

      • Do not disassemble the camshaft timing gear.

    3. A01GN8CE01

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

      Note

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

    4. Remove the 2 bolts. Then, with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket.

    5. Remove the No. 1 and No. 2 chains from the gears.

  31. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01GKY1

      Remove the 2 bolts and chain tensioner.

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


    1. A01GKF3E01

      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 hole.

    3. A01GL6T

      Remove the 2 bolts and chain tensioner.

  33. REMOVE CHAIN TENSIONER SLIPPER (for Bank 2)

  34. REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 2)


    1. A01GLQT

      Remove the 2 bolts and vibration damper.

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


    1. A01GNBIE01

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

    2. A01GJWAE01

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt with a 12 mm hexagon wrench.

      Note


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

      • Do not disassemble the camshaft timing gear.

    3. A01GHUCE01

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

      Note

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

    4. Remove the 2 bolts. Then, with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket.

    5. Remove the No. 1 and No. 2 chains from the gears.

  36. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01GI8Y

      Remove the 2 bolts and chain tensioner.

  37. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A01GL39

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

  38. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A01GKY8E01

      Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

    2. A01GMRQE01

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

    3. A01GLQQE01

      Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 7 bearing caps.

      Note

      Arrange the removed parts in the correct order.

    5. Remove the No. 1 and No. 2 camshafts.

  39. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 2)


    1. A01GIBB

      Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  40. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A01GKE7E01

      Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

    2. A01GMMXE01

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

    3. A01GL0WE01

      Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 7 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

    5. Remove the No. 3 and No. 4 camshafts.

  41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 1)


    1. A01GMPL

      Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. Remove the 32 valve rocker arms from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  43. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 32 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  44. REMOVE VALVE STEM CAP


    1. Remove the 32 valve stem caps from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

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


    1. A01GK0AE01

      Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

    2. A01GHT8E01

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

      Note


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

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

      Tech Tips

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

    3. Remove the cylinder head and gasket.

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


    1. A01GL5KE01

      Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

    2. A01GJN2E01

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

      Note


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

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

      Tech Tips

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

    3. Remove the cylinder head and gasket.

  47. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01GK1R

      Remove the 2 water jacket spacers from the cylinder head.

      Note

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

  48. REMOVE OIL RETURN PIPE GASKET


    1. A01GJTI

      Using a screwdriver, pry out the oil return pipe gasket.

      Tech Tips

      Tape the screwdriver tip before use.

  49. REMOVE NO. 1 HEAT EXCHANGER COVER


    1. A01GM4ZE01

      Remove the bolt.

    2. A01GNWDE01

      Remove the 11 bolts and 2 nuts.

    3. A01GHZ4

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

      Tech Tips

      Tape the screwdriver tip before use.

  50. REMOVE VENTILATION PIPE GASKET


    1. A01GHM8

      Using a screwdriver, pry out the ventilation pipe gasket.

      Tech Tips

      Tape the screwdriver tip before use.

  51. REMOVE OIL PAN PROTECTOR (for 2WD)


    1. A01GIM0

      Remove the 2 nuts and oil pan protector.

  52. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01GNAGE01

      for 2WD:

      Remove the 15 bolts and 2 nuts.

    2. A01GIZZE01

      for AWD:

      Remove the 13 bolts and 2 nuts.

    3. A01GIYO

      Insert the blade of oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

      Note

      Be careful not to damage the contact surfaces of the oil pans.

  53. REMOVE OIL PAN SUB-ASSEMBLY


    1. for 2WD:


      1. A01GNSRE01

        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. A01GIA8E02

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

        Note

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

        Tech Tips

        Tape the screwdriver tip before use.

    2. A01GMCPE01

      for AWD:


      1. 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. A01GNAJE01

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

        Note

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

        Tech Tips

        Tape the screwdriver tip before use.

  54. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01GLLF

      for 2WD:

      Remove the 8 bolts and baffle plate.

    2. A01GHXR

      for AWD:

      Remove the 4 bolts and baffle plate.

  55. REMOVE NO. 2 OIL PAN BAFFLE PLATE (for AWD)


    1. A01GL3F

      Remove the 4 bolts and baffle plate.

  56. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01GJT0E01

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

  57. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01GJWG

      Remove the 6 bolts.

    2. A01GK3O

      Using a screwdriver, pry out the oil seal retainer.

      Tech Tips

      Tape the screwdriver tip before use.

  58. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY


    1. A01GLNX

      Remove the bolt and oil drain pipe.

    2. Remove the O-ring.

  59. REMOVE NO. 1 VENTILATION CONNECTOR


    1. A01GNPKE01

      Remove the ventilation connector.

      Tech Tips

      When removing the ventilation connector, the ventilation tube may come off the ventilation connector. If this occurs, do not forget to remove it from the cylinder block.

      If the ventilation tube comes off, check for deformation and damage. If normal, attach the ventilation tube to the ventilation connector. If deformed or damaged, replace the ventilation connector assembly.

  60. REMOVE OIL PAN STUD BOLT

    Tech Tips

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