ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap sub-assembly.

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

  2. REMOVE OIL FILLER CAP HOUSING


    1. A015YK9

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

  3. REMOVE SPARK PLUG


    1. A0162KA

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

  4. REMOVE OIL PAN DRAIN PLUG


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

  5. REMOVE VVT SENSOR


    1. for Bank 1:


      1. A0160ZB

        Remove the 2 bolts and 2 VVT sensors.

    2. for Bank 2:


      1. A015YXS

        Remove the 2 bolts and 2 VVT sensors.

  6. REMOVE CAMSHAFT POSITION SENSOR


    1. A015YY8

      Remove the bolt and camshaft position sensor.

  7. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01606L

      Remove the bolt and crankshaft position sensor.

  8. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY LH


    1. A0162EI

      Remove the bolt and camshaft timing oil control valve assembly LH.

    2. Remove the O-ring from the camshaft timing oil control valve assembly LH.

  9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH


    1. A01601H

      Remove the bolt and camshaft timing oil control valve assembly RH.

    2. Remove the O-ring from the camshaft timing oil control valve assembly RH.

  10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A0163BBE01

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

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

  11. REMOVE CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY LH (for Bank 1)


    1. A0160VO

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

    2. Remove the O-ring from the camshaft timing control motor assembly LH.

  12. REMOVE CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY RH (for Bank 2)


    1. A01637C

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

    2. Remove the O-ring from the camshaft timing control motor assembly RH.

  13. REMOVE FRONT WATER BY-PASS JOINT


    1. A01633J

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

  14. REMOVE OIL FILTER ELEMENT


    1. A0161FLE02

      Using a SST, temporarily loosen the oil filter cap by approximately 4 turns.

      SST
      09228-06501

      Tech Tips

      Make sure that the oil filter cap ribs are vertical, this will allow the engine oil to drain from the gap between the oil filter cap and the housing.

    2. Remove the oil filter cap.

    3. A015Z1KE01

      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 for the O-ring on the cap.

  15. REMOVE OIL COOLER ASSEMBLY


    1. A0162F6E01

      Remove the bolt.

    2. Remove the union bolt, gasket and oil cooler assembly.

  16. REMOVE OIL FILTER BRACKET


    1. A015ZVB

      Remove the 2 bolts and oil filter bracket stay.

    2. A016253

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

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

  17. REMOVE CRANKSHAFT PULLEY


    1. A0162CBE02

      Using SST, loosen the crankshaft pulley set bolt.

      SST
      09213-38010
      09330-00021

      Tech Tips

      Loosen the crankshaft pulley set bolt until 2 to 3 threads remain threaded to the crankshaft.

    2. A0162ZAE01

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05031 )

      Tech Tips

      Apply grease to the threads and tip of the SST center bolt.

  18. REMOVE NO. 1 V-BANK COVER BRACKET (for Bank 1)


    1. A01613K

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

  19. REMOVE NO. 1 V-BANK COVER BRACKET (for Bank 2)


    1. A015ZEC

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

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


    1. A0163HNE01

      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

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

    3. A0161DZ

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

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


    1. A01604XE01

      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

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

    3. A015Z76

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

  22. REMOVE SPARK PLUG TUBE GASKET


    1. A0161B9

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

      Tech Tips

      Tape the screwdriver tip before use.

  23. REMOVE OIL CONTROL VALVE FILTER


    1. for Bank 1:


      1. A0160ZC

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

    2. for Bank 2:


      1. A0160SW

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

  24. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A0160D4

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

  25. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A0162G0E01

      Remove the 30 bolts and nut shown in the illustration.

    2. A0161PG

      Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly 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.

    3. A01615S

      Remove the oil pump gasket from the cylinder block.

    4. A015ZXR

      Remove the O-ring from the cylinder block.

  26. REMOVE INLET WATER PIPE


    1. A015ZWJ

      Remove the inlet water pipe.

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

  27. REMOVE WATER PUMP ASSEMBLY


    1. A0163JD

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

  28. REMOVE NO. 1 OIL PIPE


    1. A0160ZR

      Remove the 2 bolts and No. 1 oil pipe.

    2. Remove the oil pipe seal and O-ring from the No. 1 oil pipe.

  29. REMOVE NO. 2 OIL PIPE


    1. A015YVU

      Remove the 2 bolts and No. 2 oil pipe.

    2. Remove the oil pipe seal and O-ring from the No. 2 oil pipe.

  30. REMOVE NO. 3 OIL PIPE


    1. A0161C4

      Remove the 2 bolts and No. 3 oil pipe.

    2. Remove the O-ring from the No. 3 oil pipe.

  31. REMOVE SCAVENGING PUMP ASSEMBLY


    1. A016144

      Remove the 6 bolts, scavenging pump assembly and gasket.

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


    1. A0162Y0

      Using screwdriver, remove the timing gear case or timing chain case oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  33. 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 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.

      A0162ITE03

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


    1. A0160TRE01

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

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

    3. A0160XY

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

    4. Remove the chain tensioner gasket.

  35. REMOVE CHAIN TENSIONER SLIPPER (for Bank 1)


    1. A015Z64

      Remove the chain tensioner slipper.

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


    1. A0160SV

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

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


    1. A0160R4E01

      While pushing down the No. 3 chain tensioner assembly, insert a φ1.0 mm (0.0394 in.) pin into the hole to fix it in place.

    2. A0162V1E01

      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. A0161AWE01

      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 chain sub-assembly and No. 2 chain sub-assembly still connected to the gears, remove the camshaft timing 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.

  38. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY (for Bank 1)


    1. A015ZAP

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

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


    1. A0162L2E01

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

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

    3. A0162ED

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

  40. REMOVE CHAIN TENSIONER SLIPPER (for Bank 2)


    1. A015YU9

      Remove the chain tensioner slipper.

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


    1. A015ZZV

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

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


    1. A0163JTE01

      While raising up the No. 2 chain tensioner, insert a φ1.0 mm (0.0394 in.) pin into the hole to fix it in place.

    2. A015Z8UE01

      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. A015YLTE01

      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 chain sub-assembly and No. 2 chain sub-assembly still connected to the gears, remove the camshaft timing 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.

  43. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY (for Bank 2)


    1. A0160U1

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

  44. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A015YXO

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

  45. REMOVE OIL REFLECTOR PLATE LH (for Bank 1)


    1. A0161NQ

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

  46. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

    Note

    When rotating the camshafts without the timing chains installed, be careful to ensure that the valves do not contact the pistons. If contact occurs between the valves and pistons, damage may result.


    1. A0162QDE01

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

    2. A0160P5E01

      Uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    3. Remove the 8 bearing caps.

      Note

      Arrange the removed parts in the correct order.

  47. REMOVE NO. 3 CAMSHAFT


    1. Remove the No. 3 camshaft from the cylinder head sub-assembly.

  48. REMOVE NO. 4 CAMSHAFT


    1. Remove the No. 4 camshaft from the cylinder head sub-assembly.

  49. REMOVE OIL REFLECTOR PLATE RH (for Bank 2)


    1. A0162QZ

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

  50. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

    Note

    When rotating the camshafts without the timing chains installed, be careful to ensure that the valves do not contact the pistons. If contact occurs between the valves and pistons, damage may result.


    1. A0160AHE01

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

    2. A0162T9E01

      Uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    3. Remove the 8 bearing caps.

      Note

      Arrange the removed parts in the correct order.

  51. REMOVE CAMSHAFT


    1. Remove the camshaft from the cylinder head sub-assembly.

  52. REMOVE NO. 2 CAMSHAFT


    1. Remove the No. 2 camshaft from the cylinder head sub-assembly.

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


    1. A0162R9

      Remove the 32 No. 1 valve rocker arm sub-assembly from the cylinder heads.

      Tech Tips

      Arrange the removed parts in the correct order.

  54. REMOVE VALVE ROCKER ARM PIVOT


    1. Remove the 32 valve rocker arm pivots from the cylinder head sub-assembly.

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


    1. A01610W

      Remove the 3 bolts and camshaft housing.

    2. A015ZR9E01

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

    3. A0162SME01

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

      Note


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

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

      Tech Tips

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

    4. Remove the cylinder head sub-assembly.

  56. REMOVE NO. 2 CYLINDER HEAD GASKET (for Bank 1)


    1. Remove the No. 2 cylinder head gasket.

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


    1. A015ZTK

      Remove the 3 bolts and camshaft housing.

    2. A0161ZUE01

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

    3. A015ZSLE01

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

      Note


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

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

      Tech Tips

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

    4. Remove the cylinder head sub-assembly.

  58. REMOVE CYLINDER HEAD GASKET (for Bank 2)


    1. Remove the cylinder head gasket.

  59. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A015ZIO

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

      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.

  60. REMOVE HEAT EXCHANGER ASSEMBLY


    1. A0160EA

      Remove the bolt.

    2. A0163COE01

      Remove the 11 bolts and 2 nuts.

    3. A01635U

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

      Tech Tips

      Tape the screwdriver tip before use.

  61. REMOVE VENTILATION PIPE GASKET


    1. A01600E

      Using a screwdriver, pry out the ventilation pipe gasket.

      Tech Tips

      Tape the screwdriver tip before use.

  62. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A0162P0E01

      Remove the 15 bolts and 2 nuts.

    2. A015Z7X

      Insert the blade of an oil pan 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.

  63. REMOVE OIL PAN SUB-ASSEMBLY


    1. A0160X1E01

      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. A0160Z2E01

      Remove the oil pan sub-assembly 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 sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  64. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A015YS5

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

  65. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A015ZUA

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

  66. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A0160LU

      Remove the 6 bolts.

    2. A016372

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

  67. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY


    1. A0162ZT

      Remove the bolt and oil drain pipe sub-assembly.

    2. Remove the O-ring.