ENGINE UNIT DISASSEMBLY


  1. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01DTR2

      Using a 24 mm deep socket wrench, remove the oil pressure switch.

  2. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A01DN1Q

      Using a 19 mm deep socket wrench, remove the sensor.

    2. Remove the gasket from the sensor.

  3. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A01DNZA

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

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

  4. REMOVE VVT SENSOR


    1. A01DU68

      LH:

      Remove the 2 bolts and 2 VVT sensors.

    2. A01DPIG

      RH:

      Remove the 2 bolts and 2 VVT sensors.

  5. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01DOGB

      Remove the bolt and crankshaft position sensor.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH


    1. A01DO1Y

      LH:

      Remove the 2 bolts and 2 oil control valves.

    2. A01DO0A

      RH:

      Remove the 2 bolts and 2 oil control valves.

  7. REMOVE OIL FILLER CAP HOUSING


    1. A01DOQ3

      Remove the oil filler cap.

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

  8. REMOVE NO. 1 OIL PIPE


    1. A01DTGB

      Remove the 2 oil pipe unions, oil control valve filter LH, 3 gaskets and No. 1 oil pipe.

      Note

      Do not touch the mesh when removing the oil control valve filter.

  9. REMOVE NO. 2 OIL PIPE


    1. A01DSUX

      Remove the 2 oil pipe unions, oil control valve filter RH, 3 gaskets and No. 2 oil pipe.

      Note

      Do not touch the mesh when removing the oil control valve filter.

  10. REMOVE OIL FILTER ELEMENT


    1. A01DSORE09
      Text in Illustration
      *1 Pipe
      *2 Hose

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

    2. A01DN0V

      Remove the oil filter drain plug.

    3. A01DTY9E01
      Text in Illustration
      *1 Cap
      *2 Valve
      *3 Pipe
      *4 O-Ring
      *5 Hose

      Install the pipe to the oil filter cap.

      Tech Tips

      Use a container to catch the draining oil.

      Note

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

    4. A01DQWA

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

    5. A01DO41E01
      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. A01DNRCE03
      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 for the O-ring in the cap.

  11. REMOVE OIL FILTER BRACKET


    1. A01DPWNE01
      Text in Illustration
      *A w/ Oil Cooler
      *B w/o Oil Cooler

      Remove the 2 nuts, bolt, oil filter bracket and gasket.

  12. REMOVE WATER INLET HOUSING


    1. A01DQTV

      Disconnect the 3 water by-pass hoses.

    2. A01DP1Z

      Remove the 5 bolts and water inlet housing.

    3. A01DQ0A

      Remove the O-ring and gasket from the water outlet pipe and water pump.

    4. A01DU4S

      Remove the 3 water by-pass hoses.

  13. REMOVE REAR WATER BY-PASS JOINT


    1. A01DO7DE01

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

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

  14. REMOVE SPARK PLUG


    1. Remove the 6 spark plugs.

  15. REMOVE PCV VALVE SUB-ASSEMBLY


    1. Remove the PCV valve hose.

    2. A01DNKA

      Remove the PCV valve.

  16. REMOVE CRANKSHAFT PULLEY


    1. A01DMJWE04

      Using SST, hold the crankshaft pulley and loosen the pulley bolt. Continue to loosen the bolt until only 2 or 3 threads are screwed into the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A01DMDHE02

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05031 )

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01DMGW

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

      Tech Tips

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

    2. A01DS0A

      Remove the 3 gaskets.

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01DT2W

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

      Tech Tips

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

    2. A01DMA5

      Remove the 3 gaskets.

  19. REMOVE SPARK PLUG TUBE GASKET

    A01DM0U

    1. Bend the ventilation baffle plate claws on the cylinder head cover to an angle of 90° or more.

      Text in Illustration
      A01DQPB Pry

    2. 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.

  20. REMOVE ENGINE OIL LEVEL SENSOR (w/ Warmer)


    1. Disconnect the connector.

    2. A01DSE6

      Remove the 4 bolts and sensor.

    3. Cut away part of the gasket and remove the gasket from the engine oil level sensor.

      Tech Tips

      Remove only the outer part of the gasket.

  21. REMOVE OIL PAN DRAIN PLUG


    1. Remove the drain plug and gasket.

  22. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01DMCV

      Remove the 10 bolts and 2 nuts.

      Tech Tips

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

    2. A01DR8DE02
      Text in Illustration
      *1 Oil Pan Seal Cutter

      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.

      Note

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

  23. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01DQTT

      Remove the 2 nuts, oil strainer and gasket.

  24. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01DNV4

      Remove the 17 bolts and 2 nuts.

      Tech Tips

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

    2. A01DTIFE01
      Text in Illustration
      *1 LH Side
      *2 RH Side
      *a Pry

      Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block as shown in the illustration.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

    3. A01DP9E

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

  25. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01DO5V

      Remove the 6 bolts and No. 1 oil pan baffle plate.

  26. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01DU8DE04
      Text in Illustration
      *a Pry

      Remove the 5 bolts and 2 nuts.

    2. Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and crankshaft bearing cap.

      Tech Tips

      Tape the screwdriver tip before use.

  27. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A01DOH0E03

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

      Note

      Be careful not to damage the rear oil seal retainer.

  28. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01DO1R

      Remove the 26 bolts and the 2 nuts.

    2. A01DM7K

      Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

    3. A01DRPF

      Remove the oil pump gasket from the cylinder block.

  29. REMOVE WATER PUMP ASSEMBLY


    1. A01DRFN

      Remove the 8 bolts, water pump and gasket.

  30. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. Using a screwdriver and wooden block, pry out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

      Do not damage the surface of the oil seal press fit hole.

  31. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the pulley set bolt.

    2. A01DS98E01
      Text in Illustration
      *1 Center Line
      *2 Timing Mark
      *3 Sensor Plate

      Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression).

    3. A01DUKVE01
      Text in Illustration
      *1 Timing Mark

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

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

  32. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01DPI4E05
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate
      *3 Pin

      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 pin of φ1.27 mm (0.0500 in.) into the stopper plate hole.

    3. A01DPLQE02

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

  33. REMOVE CHAIN TENSIONER SLIPPER


    1. A01DTP5

      Remove the chain tensioner slipper.

  34. REMOVE NO. 1 CHAIN SUB-ASSEMBLY


    1. A01DSDHE01
      Text in Illustration
      *1 Center Line
      *2 Timing Mark
      *3 Sensor Plate

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

    2. Remove the pulley set bolt.

    3. A01DNU4

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

    4. A01DQWBE12

      Turn the camshaft timing gear assembly on bank 1 clockwise approximately 60° so that it is as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks.

    5. Remove the chain sub-assembly.

      Text in Illustration
      *A for Bank 1

  35. REMOVE NO. 1 IDLE GEAR SHAFT


    1. A01DOQH

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

  36. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01DO27

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

  37. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A01DMT1

      Remove the 2 No. 2 chain vibration dampers.

  38. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01DPACE01

      Remove the crankshaft timing sprocket.

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


    1. A01DSSDE01
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

      While raising the No. 2 chain tensioner assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to hold the No. 2 chain tensioner assembly.

    2. A01DU7SE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, loosen the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

      SST
      09922-10010

      Note

      Do not loosen the other 4 bolts. If any of the 4 bolts is loosened, replace the camshaft timing gear assembly and/or camshaft timing exhaust gear assembly with a new one.

    3. Remove the 2 bolts and camshaft timing gear assembly together with the No. 2 chain.

  40. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01DQBJ

      Remove the bolt and No. 2 chain tensioner assembly.

  41. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A01DRCME06
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A01DRMME01

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

    3. A01DQUXE01

      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 camshaft level.

    4. Remove the 5 camshaft bearing caps.

    5. Remove the camshaft and No. 2 camshaft.

  42. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01DQY0E01
      Text in Illustration
      *1 Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

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


    1. A01DUJ0E01
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

      While pushing down the No. 3 chain tensioner assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to hold the No. 3 chain tensioner assembly.

    2. A01DNCKE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, loosen the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

      SST
      09922-10010

      Note

      Do not loosen the other 4 bolts. If any of the 4 bolts is loosened, replace the camshaft timing gear assembly and/or camshaft timing exhaust gear assembly with a new one.

    3. Remove the 2 bolts and camshaft timing gear together with the No. 2 chain.

  44. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01DUQV

      Remove the bolt and No. 3 chain tensioner assembly.

  45. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A01DQEOE01
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A01DUPQE01

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

    3. A01DPYDE01

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

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 5 camshaft bearing caps.

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

  46. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01DO06E01
      Text in Illustration
      *1 Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

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


    1. Remove the 24 valve rocker arms from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  48. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 24 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  49. REMOVE VALVE STEM CAP


    1. Remove the 24 valve stem caps from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  50. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01DNL4E01

      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 washers into the cylinder head sub-assembly.

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

      Tech Tips

      Arrange the removed parts in the correct order.

    2. Remove the cylinder head sub-assembly.

  51. REMOVE CYLINDER HEAD LH


    1. A01DPX3E01

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

    2. A01DPO7E01

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

      Note


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

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

      Tech Tips

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

    3. Remove the cylinder head LH.

  52. REMOVE CYLINDER HEAD GASKET

  53. REMOVE NO. 2 CYLINDER HEAD GASKET

  54. REMOVE NO. 1 WATER OUTLET PIPE


    1. A01DT9M

      Detach the 3 wire harness clamps.

    2. Remove the 2 nuts, bolt and water outlet pipe.

  55. REMOVE KNOCK SENSOR


    1. A01DQL7

      Disconnect the 2 sensor connectors.

    2. Remove the 2 bolts and 2 sensors.

  56. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    A01DRPA

    1. 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.

  57. REMOVE TAPER SCREW PLUG

    Note

    It is not necessary to remove a taper screw plug unless it is being replaced.

  58. REMOVE STRAIGHT PIN

    Note

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

  59. REMOVE RING PIN

    Note

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

  60. REMOVE STUD BOLT

    Note

    It is not necessary to remove a stud bolt unless it is being replaced.