ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

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  2. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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  3. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. for Type A:


      1. A01X6ZN

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

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

    2. for Type B:


      1. A01X1D4

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

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

  4. REMOVE VVT SENSOR (for Intake Side of Bank 1)

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  5. REMOVE VVT SENSOR (for Exhaust Side of Bank 1)

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  6. REMOVE VVT SENSOR (for Intake Side of Bank 2)

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  7. REMOVE VVT SENSOR (for Exhaust Side of Bank 2)

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  8. REMOVE CRANKSHAFT POSITION SENSOR

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  9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1)

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  10. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1)

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  11. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2)

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  12. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2)

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  13. REMOVE OIL FILLER CAP HOUSING


    1. A01X6DI

      Remove the oil filler cap.

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

  14. REMOVE NO. 1 OIL PIPE

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  15. REMOVE NO. 2 OIL PIPE

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  16. REMOVE OIL FILTER ELEMENT

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  17. REMOVE OIL FILTER BRACKET

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  18. REMOVE WATER INLET HOUSING

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  19. REMOVE REAR WATER BY-PASS JOINT


    1. A01X5L7

      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.

  20. REMOVE SPARK PLUG

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  21. REMOVE PCV VALVE SUB-ASSEMBLY

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  22. REMOVE CRANKSHAFT PULLEY

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  23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01XBPH

      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. A01X7YB

      Remove the 3 gaskets.

  24. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01XAKT

      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. A01WZYX

      Remove the 3 gaskets.

  25. REMOVE SPARK PLUG TUBE GASKET

    A01XBDC

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

      Text in Illustration
      B001XPG 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.

  26. REMOVE ENGINE OIL LEVEL SENSOR

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  27. REMOVE OIL PAN DRAIN PLUG


    1. Remove the drain plug and gasket.

  28. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

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  29. REMOVE OIL STRAINER SUB-ASSEMBLY

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  30. REMOVE OIL PAN SUB-ASSEMBLY

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  31. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01X4TJ

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

  32. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01X1F9E08
      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.

  33. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A01X1MV

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

      Note

      Be careful not to damage the rear oil seal retainer.

  34. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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  35. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01X702

      Remove the 8 bolts, engine water pump and gasket.

  36. REMOVE FRONT CRANKSHAFT OIL SEAL

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  37. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the pulley set bolt.

    2. A01X7KGE04
      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. 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.

      A01X0SZE01

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

      Text in Illustration
      *1 Timing Mark

  38. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01X9XHE20
      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 with a diameter of 1.27 mm (0.0500 in.) into the stopper plate hole.

    3. A01X643E03

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

  39. REMOVE CHAIN TENSIONER SLIPPER


    1. A01WYXC

      Remove the chain tensioner slipper.

  40. REMOVE CHAIN SUB-ASSEMBLY


    1. A01X81QE04
      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. A01X6F0

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

    4. A01X8WFE01

      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

  41. REMOVE NO. 1 IDLE GEAR SHAFT


    1. A01X6EH

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

  42. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01XAXZ

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

  43. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A01XA01

      Remove the 2 No. 2 chain vibration dampers.

  44. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01XB3Z

      Remove the crankshaft timing sprocket.

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


    1. A01WZO8E04
      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. A01X99EE01
      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.

  46. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01XACZ

      Remove the bolt and No. 2 chain tensioner assembly.

  47. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A01X056E06
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A01XAEWE07

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

    3. A01X4J4E04

      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.

  48. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01X9NIE04
      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.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. A01X2YRE06
      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. A01X1QWE01
      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.

  50. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01X3WS

      Remove the bolt and No. 3 chain tensioner assembly.

  51. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A01X4OZE04
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A01X8WQE07

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

    3. A01X0PHE04

      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.

  52. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01X0S1E04
      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.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  53. 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.

  54. 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.

  55. 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.

  56. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  57. REMOVE CYLINDER HEAD LH

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  58. REMOVE CYLINDER HEAD GASKET

  59. REMOVE NO. 2 CYLINDER HEAD GASKET

  60. REMOVE NO. 1 WATER OUTLET PIPE

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  61. REMOVE KNOCK CONTROL SENSOR

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  62. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    A01X5EU

    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.

  63. REMOVE TAPER SCREW PLUG

    Note

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

  64. REMOVE STRAIGHT PIN

    Note

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

  65. REMOVE RING PIN

    Note

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

  66. REMOVE STUD BOLT

    Note

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