ENGINE UNIT DISASSEMBLY

Tech Tips

When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side.


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  2. REMOVE OIL FILLER CAP HOUSING


    1. A01GXY6

      Remove the 2 bolts, filler cap housing and gasket.

  3. REMOVE SPARK PLUG


    1. A01H0YU

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

  4. REMOVE VVT SENSOR


    1. A01H234

      for Bank 1:

      Remove the 2 bolts and 2 VVT sensors.

    2. A01GWHF

      for Bank 2:

      Remove the 2 bolts and 2 VVT sensors.

  5. REMOVE CAMSHAFT POSITION SENSOR


    1. A01H1NV

      Remove the bolt and camshaft position sensor.

  6. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01GWV4

      Remove the bolt and crankshaft position sensor.

  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01GWFU

      for Bank 1:

      Remove the bolt and oil control valve.

      Remove the O-ring from the valve.

    2. A01GX96

      for Bank 2:

      Remove the bolt and oil control valve.

      Remove the O-ring from the valve.

  8. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A01GX72E01

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

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

  9. REMOVE CAMSHAFT TIMING CONTROL WITH EDU MOTOR ASSEMBLY LH

    A01GZRR

    1. Disconnect the 2 cam timing control with EDU motor assembly LH connectors and wire harness clamp.

    2. A01GYDH

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

      Note

      Do not allow foreign matter to contact the oil seal face of the cam 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

    A01H15TE01

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

    2. Remove the bolt and engine wire bracket.

    3. A01GW8R

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

      Note

      Do not allow foreign matter to contact the oil seal face of the cam 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 WIRE HARNESS CLAMP BRACKET

    A01GXLQ

    1. Remove the bolt and wire harness clamp bracket.

  12. REMOVE OIL FILTER ELEMENT


    1. A01H1A8E11
      Text in Illustration
      *1 Pipe
      *2 Hose

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

    2. A01GYQZ

      Remove the oil filter drain plug.

    3. A01H20GE02
      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. A01GYV8

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

    5. A01GYQHE02
      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. A01GXE8E03
      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 cap's O-ring by hand, without using any tools, to prevent damage to the cap's O-ring groove.

  13. REMOVE OIL FILTER BRACKET


    1. A01GYZS

      Remove the 3 bolts, filter bracket and 2 gaskets.

  14. REMOVE WATER PUMP PULLEY


    1. A01GXZLE01

      Using SST, hold the water pump pulley.

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

    2. Remove the 4 bolts and water pump pulley.

  15. REMOVE FRONT WATER BY-PASS JOINT


    1. A01H0BH

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

  16. REMOVE SPARK PLUG TUBE GASKET


    1. A01GWG8E01

      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. A01H0U2E05

      Remove the fuel pump spacer.

    2. Remove the fuel pump spacer gasket.

    3. Remove the 15 bolts in the order shown in the illustration. Then remove the 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.

    4. A01GZM6

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

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A01GYY9E04

      Remove the fuel pump spacer.

    2. Remove the fuel pump spacer gasket.

    3. Remove the 15 bolts in the order shown in the illustration. Then remove the 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.

    4. A01H1IN

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

  19. REMOVE OIL CONTROL VALVE FILTER


    1. for LH:


      1. A01GY9SE02

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

    2. for RH:


      1. A01GZXRE02

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

  20. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01GYJT

      Remove the bolt and belt tensioner.

  21. REMOVE CRANKSHAFT PULLEY


    1. A01GY1AE01

      Using SST, loosen the crankshaft pulley set bolt until 2 or 3 threads are engaged.

      SST
      09213-54015   ( 90119-08216 )
      09330-00021
    2. A01GZW2E01

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

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

  22. REMOVE WATER PUMP


    1. A01GX0Q

      Remove the 9 bolts, engine water pump and gasket.

  23. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01H0LK

      Remove the 2 plugs and 2 gaskets.

    2. A01H1IOE01

      Remove the 30 bolts and nut shown in the illustration.

    3. A01GZMN

      Remove the timing chain cover by prying between the timing chain cover and cylinder head or 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. A01GW7S

      Remove the oil pump gasket from the cylinder block.

    5. A01GZLH

      Remove the O-ring from the oil pan.

  24. REMOVE WATER INLET PIPE


    1. A01GY03

      Remove the water inlet pipe.

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

  25. REMOVE FRONT CRANKSHAFT OIL SEAL

    A01GWSV

    1. Place the timing chain cover on wooden blocks.

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  26. SET NO. 1 CYLINDER TO TDC / COMPRESSION


    1. Temporarily install the crankshaft pulley 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.

    3. Remove the crankshaft pulley bolt.

      A01GZIXE01

  27. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH


    1. A01H205E01

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

    2. A01GZB8E01

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

    3. A01GYAO

      Remove the 2 bolts, chain tensioner and gasket.

  28. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

  29. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH

    A01GWQP

    Remove the 2 bolts and chain vibration damper.

  30. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH


    1. A01GZF5E02

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

    2. A01GX2FE02

      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. A01H0BNE02

      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, camshaft timing exhaust gear and crankshaft timing sprocket LH.

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

  31. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01H1RVE02

      Remove the 2 bolts and chain tensioner.

  32. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH


    1. A01GXFGE01

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

    2. A01H0XAE01

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

    3. A01H090

      Remove the 2 bolts and chain tensioner.

  33. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

  34. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH


    1. A01GXME

      Remove the 2 bolts and vibration damper.

  35. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH


    1. A01H265E02

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

    2. A01GX4CE01

      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. A01GY96E02

      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, camshaft timing exhaust gear and crankshaft timing sprocket RH.

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

  36. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01GYVT

      Remove the 2 bolts and chain tensioner.

  37. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A01GYUC

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

  38. REMOVE CAMSHAFT BEARING CAP LH


    1. A01H00UE02

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

    2. A01GXGEE01

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

    3. A01H1SUE01

      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.

  39. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01H0OL

      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 RH


    1. A01GX9KE03

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

    2. A01H0O6E01

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

    3. A01GX5AE01

      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. 1 and No. 2 camshafts.

  41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01H287

      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 LH


    1. A01H20TE01

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

    2. A01H0DSE01

      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 RH


    1. A01GYF7E01

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

    2. A01GZ9ZE01

      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. A01GZCK

      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 SUB-ASSEMBLY

    A01GYU7

    1. Using a center punch, mark the center of the tapered-head bolt.

    2. Using a drill, drill a hole in the bolt.

    3. Using a screw extractor, remove the tapered-head bolt. Then remove the standard bolt and oil return pipe.

    4. Remove the O-ring.

  49. REMOVE NO. 2 OIL RETURN PIPE

    A01GWNL

    Note

    It is not necessary to remove the No. 2 oil return pipe unless it is being replaced.

  50. REMOVE NO. 1 HEAT EXCHANGER COVER


    1. A01GWTUE01

      Remove the 11 bolts and 2 nuts.

    2. A01H1K5

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

      Tech Tips

      Tape the screwdriver tip before use.

  51. REMOVE VENTILATION PIPE GASKET


    1. A01GXVO

      Using a screwdriver, pry out the ventilation pipe gasket.

      Tech Tips

      Tape the screwdriver tip before use.

  52. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01GXH9E01

      Remove the 13 bolts and 2 nuts.

    2. A01GY71

      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 NO. 1 OIL PAN SUB-ASSEMBLY


    1. A01GZKCE01

      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. A01GYSSE01

      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. A01GY58

      Remove the 4 bolts and baffle plate.

  55. REMOVE NO. 2 OIL PAN BAFFLE PLATE


    1. A01H0GV

      Remove the 4 bolts and baffle plate.

  56. REMOVE ENGINE OIL LEVEL SENSOR


    1. A01GW4D

      Disconnect the engine oil level sensor connector.

    2. Remove the 4 bolts.

    3. A01GYY5

      Rotate the engine oil level sensor 180° and remove it.

    4. A01GWDJE02

      Cut off the gasket as shown in the illustration.

    5. Remove the gasket from the oil level sensor.

      Tech Tips

      After cutting away the parts of the gasket shown in the illustration, remove only the outer part of the gasket.

  57. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01GW7P

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

  58. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01GY5M

      Remove the 6 bolts.

    2. A01GXXX

      Using a screwdriver, pry out the oil seal retainer.

      Tech Tips

      Tape the screwdriver tip before use.

  59. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY


    1. A01GXL5

      Remove the bolt and oil drain pipe.

    2. Remove the O-ring.

  60. REMOVE NO. 1 VENTILATION CONNECTOR


    1. A01GXVAE01

      Remove the ventilation connector.

      Tech Tips

      When removing the ventilation connector, the ventilation tube may come off of the ventilation connector. If this occurs, remove the ventilation tube from the cylinder block and check for deformation and damage. If normal, connect the ventilation tube to the ventilation connector. If deformed or damaged, replace the ventilation connector assembly.

  61. REMOVE REAR CRANKSHAFT OIL SEAL

    A01GY4SE02

    1. Place the oil seal retainer on wooden blocks.

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

  62. REMOVE STRAIGHT PIN

    Note

    It is not necessary to remove the straight pins unless they are being replaced.

  63. REMOVE STUD BOLT

    Note

    If the stud bolts are deformed or their threads are damaged, replace them.