OIL PUMP REMOVAL


  1. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A0160IP

      Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 clips on the front of the cover. Continue to raise the cover to disengage the 2 clips on the rear of the cover and remove the V-bank cover sub-assembly.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  2. REMOVE COOL AIR INTAKE DUCT SEAL


    1. A015ZFO

      Remove the 9 clips and cool air intake duct seal.

  3. REMOVE ENGINE ROOM SIDE COVER LH (for LHD)


    1. A016120

      Remove the 5 clips and engine room side cover LH.

  4. REMOVE ENGINE ROOM SIDE COVER LH (for RHD)


    1. A015Z63

      Remove the 4 clips and engine room side cover LH.

  5. REMOVE ENGINE ROOM SIDE COVER RH (for LHD)


    1. A0161AL

      Remove the 3 clips and engine room side cover RH.

  6. REMOVE ENGINE ROOM SIDE COVER RH (for RHD)


    1. A015YK3

      Remove the 4 clips and engine room side cover RH.

  7. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  8. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine speed of approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.

    4. Stop the engine.

    5. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

  9. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  10. REMOVE ENGINE UNDER COVER

  11. REMOVE NO. 2 ENGINE UNDER COVER

  12. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and drain the engine oil into a container.

    3. Install a new gasket and the oil pan drain plug.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  13. DRAIN ENGINE COOLANT


    1. Loosen the radiator drain cock plug.

      CAUTION:

      Do not loosen the radiator drain cock plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

      Tech Tips

      Collect the coolant in a container and dispose of it according to local regulations.

    2. A0161WSE01

      Remove the radiator reservoir cap, and using a 6 mm socket hexagon wrench, remove the vent plug.

    3. Drain coolant.

    4. Loosen the 2 cylinder block drain cock plugs.

      A01603GE01

  14. DRAIN AUTOMATIC TRANSMISSION FLUID


    1. Remove the drain plug and gasket, and drain the ATF.

    2. Install a new gasket and the drain plug.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  15. REMOVE NO. 1 AIR CLEANER INLET


    1. A01612G

      Remove the bolt, clip and No. 1 air cleaner inlet.

  16. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A015YRW

      Loosen the 2 hose clamps and separate the 2 ventilation hoses.

    2. A01622I

      Disconnect the mass air flow meter connector and separate the wire harness clamp.

    3. A015ZWF

      Loosen the hose clamp and separate the air cleaner hose.

    4. A015YT4

      Unlock the 2 clamps and remove the air cleaner cap sub-assembly.

  17. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A0163D8

      Remove the 2 clamps and disconnect the vacuum hose.

    2. A015ZYF

      Remove the clamp and disconnect the vacuum switching valve connector.

    3. Remove the 2 bolts and air cleaner case sub-assembly.

  18. REMOVE RADIATOR ASSEMBLY

    Click here

  19. REMOVE BATTERY (for LHD)


    1. A0162W7

      Disconnect the 2 clamps.

    2. Disconnect the cable from the positive (+) battery terminal.

    3. Remove the nut and the battery clamp.

    4. Remove the battery insulator.

    5. Remove the battery.

  20. REMOVE BATTERY (for RHD)


    1. A0163BE

      Disconnect the 2 clamps.

    2. Disconnect the cable from the positive (+) battery terminal.

    3. Remove the nut and the battery clamp.

    4. Remove the battery insulator.

    5. Remove the battery.

  21. REMOVE NO. 1 BATTERY TRAY SUPPORT

  22. REMOVE POWER STEERING ECU ASSEMBLY


    1. Release the locks of the 2 power steering ECU assembly connectors (A) and (B).

      A01625SE01

    2. Disconnect the connectors (A), (B) and (C) from the power steering ECU assembly.

    3. A016155

      Remove the 3 bolts.

    4. Remove the power steering ECU assembly.

  23. REMOVE BATTERY TRAY (for LHD)


    1. A0163HY

      Remove the 3 bolts and battery tray.

    2. A016319

      Remove the 2 bolts and nut and separate the No. 7 engine room relay block.

  24. REMOVE BATTERY TRAY (for RHD)


    1. A015ZVG

      Remove the 3 bolts and battery tray.

    2. A0162TN

      Remove the 2 bolts and nut and separate the No. 7 engine room relay block.

  25. REMOVE WIRE HARNESS CLAMP BRACKET (for LHD)


    1. A0162F8

      Remove the bolt and separate the wire harness clamp bracket.

    2. Separate the wire harness clamp from the wire harness clamp bracket.

  26. REMOVE WIRE HARNESS CLAMP BRACKET (for RHD)


    1. A015Z8N

      Remove the bolt and separate the wire harness clamp bracket.

    2. Separate the wire harness clamp from the wire harness clamp bracket.

  27. REMOVE ENGINE ROOM ECU COVER


    1. A01627R

      Remove the 3 bolts and the engine room ECU cover.

      Note


      • Remove all water from on and around the engine room ECU cover.

      • Perform the inspection indoors to avoid rain.

      • Be sure to prevent water intrusion to the ECM (connectors and screw holes).

  28. DISCONNECT WIRE HARNESS


    1. A01628L

      Remove the 3 connectors and connector clamp.

    2. A0160ZG

      Using a screwdriver, detach the claw and disconnect the No. 4 connector holder.

    3. A016370

      Disconnect the 5 connectors and grommet from the engine room ECU box.

    4. A01608K

      Disconnect the 8 connectors and 3clamps.

    5. A0163JO

      Disconnect the 5 connectors and 7clamps.

    6. Remove the 2 bolts and disconnect the 2 ground wires.

    7. Remove the No. 1 engine room relay block cover (for RHD).

    8. A015YZ0

      Remove the nut (for RHD).

    9. A015YHC

      Disconnect the clamp, detach the 2 claws and disconnect the wire harness from the engine room No. 1 relay block (for RHD).

    10. A016393

      Remove the bolt, and disconnect the ground cable.

    11. A01638W

      Remove the bolt, and disconnect the clamp and ground cable.

  29. REMOVE FUEL PUMP ASSEMBLY (for Bank 1)

    Click here

  30. REMOVE FUEL PUMP ASSEMBLY (for Bank 2)

    Click here

  31. REMOVE FUEL PUMP SPACER


    1. Remove the 2 fuel pimp spacers.

  32. REMOVE V-RIBBED BELT


    1. A0160KK

      Rotate the V-ribbed belt tensioner pulley counterclockwise to loosen the V-ribbed belt tensioner.

      Tech Tips

      The pulley bolt for the V-ribbed belt tensioner is reverse threaded.

    2. A0162C9E01

      While turning the V-ribbed belt tensioner counterclockwise, align the holes. Insert a bar of φ5 mm (0.197 in.) into the holes to secure the V-ribbed belt tensioner in place.

    3. Remove the V-ribbed belt.

  33. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE


    1. A01624LE02

      Disconnect the connector and 2 clamps.

    2. A015ZMQ

      Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the compressor.

    3. Remove the O-ring from the cooler refrigerant suction hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  34. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. A01624P

      Remove the bolt and disconnect the discharge sub-assembly from the compressor.

    2. Remove the O-ring from the discharge sub-assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  35. SEPARATE COMPRESSOR AND PULLEY


    1. A0160HC

      Remove the 2 bolts and 2 nuts.

    2. A015YMA

      Using an E8 "TORX" socket, remove the 2 stud bolts and compressor.

      Tech Tips

      Remove the compressor and pulley from the vehicle with the stud bolts remaining in the compressor.

    3. A01624A

      Remove the bolt and bracket.

  36. REMOVE GENERATOR ASSEMBLY


    1. A016244E01

      Remove nut A, and disconnect the harness from the +B terminal.

    2. Remove bolt B, and disconnect the oil cooler tube.

    3. Remove clamp C.

    4. Disconnect generator connector D.

    5. A0161DX

      Remove the nut and the wire harness bracket.

    6. A0163K8

      Remove the 2 bolts and 2 nuts.

    7. A0161MB

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

  37. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A0161UQ

      Remove the bolt and idler pulley sub-assembly.

  38. REMOVE OIL PUMP DRIVE SHAFT PULLEY


    1. A016325E01

      Using SST, hold the oil pump drive shaft pulley.

      SST
      09960-10010   ( 09962-01000, 09963-00600 )

    2. Remove the 4 bolts and oil pump drive shaft pulley.

  39. REMOVE WATER PUMP PULLEY


    1. A0160QTE01

      Using a screwdriver or an equivalent, hold the water pump pulley.

      Tech Tips

      Tape the screwdriver tip before use to avoid damage.

    2. Remove the 4 bolts and water pump pulley.

  40. DISCONNECT NO. 2 RADIATOR HOSE


    1. A0161KB

      Disconnect the No. 2 radiator hose from the water inlet housing.

  41. DISCONNECT NO. 5 WATER BY-PASS HOSE


    1. A0162ZY

      Disconnect the No. 5 water by-pass hose from the water inlet housing.

  42. DISCONNECT WATER INLET HOSE


    1. A015ZXV

      Disconnect the water inlet hose from the water inlet housing.

  43. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. A01639A

      Disconnect the No. 3 water by-pass hose from the water inlet housing.

  44. REMOVE WATER INLET HOUSING


    1. A0162EY

      Remove the 3 bolts, water inlet housing and gasket.

  45. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A0162JT

      Remove the 3 hose clamps and disconnect the 3 water by-pass hoses.

    2. Remove the 4 bolts and No. 2 water by-pass pipe sub-assembly.

  46. REMOVE IGNITION COIL ASSEMBLY


    1. Disconnect the 8 ignition coil connectors.

    2. A0160Z7E01

      Remove the 8 bolts and 8 ignition coil assemblies.

      Note

      Do not damage the ignition coil assemblies when removing them.

  47. REMOVE NO. 4 V-BANK COVER BRACKET SUB-ASSEMBLY


    1. A01635G

      Remove the nut and No. 4 V-bank cover bracket.

  48. REMOVE NO. 3 V-BANK COVER BRACKET SUB-ASSEMBLY


    1. A0163F5

      Remove the bolt and No. 3 V-bank cover bracket.

  49. REMOVE FRONT WATER BY-PASS JOINT


    1. A01633J

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

  50. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY


    1. A015ZVB

      Remove the 2 bolts and oil filter bracket stay.

    2. A0163EH

      Remove the 2 bolts, 2 nuts and oil filter bracket sub-assembly.

    3. Remove the 2 gaskets from the oil filter bracket sub-assembly.

  51. 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.

  52. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A0160SO

      Remove the crankshaft timing gear key from the crankshaft.

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


    1. A01636GE02

      Using a knife, cut through the oil seal lip.

    2. Using a screwdriver with its tip taped, pry out the oil seal.

      Note

      After removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper.

  54. 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.

  55. 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.

  56. 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.

  57. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A0160D4

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

  58. 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.

  59. 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.

  60. 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.

  61. REMOVE INLET WATER PIPE


    1. A015ZWJ

      Remove the inlet water pipe.

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

  62. 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.

  63. 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.

  64. 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.

  65. REMOVE SCAVENGING PUMP ASSEMBLY


    1. A016144

      Remove the 6 bolts, scavenging pump assembly and gasket.