ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap sub-assembly and oil filler gasket.

  2. REMOVE SPARK PLUG


    1. A01I0E3

      Remove the 6 spark plugs.

  3. REMOVE OIL PAN DRAIN PLUG


    1. A01HZ47

      Remove the oil pan drain plug and oil pan drain plug gasket.

  4. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A01HYIX

      Remove the ventilation valve sub-assembly.

  5. REMOVE VVT SENSOR


    1. Disconnect the 4 sensor connectors.

    2. A01HXZJE02
      Text in Illustration
      *a for Bank 1
      *b for Bank 2
      *c for Intake Side
      *d for Exhaust Side

      Remove the 4 bolts and 4 sensors.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. Disconnect the 4 oil control valve connectors.

    2. A01I0HME01
      Text in Illustration
      *a for Intake Side
      *b for Exhaust Side
      *c for Bank 2
      *d for Bank 1

      Remove the 4 bolts and 4 oil control valves.

    3. A01HY0DE06
      Text in Illustration
      *1 O-ring

      Remove the O-ring from each oil control valve.

  7. REMOVE CRANK POSITION SENSOR


    1. A01I092

      Disconnect the crank position sensor connector.

    2. Remove the bolt and crank position sensor.

  8. REMOVE NO. 1 OIL PIPE


    1. A01I1HFE02
      Text in Illustration
      *1 Oil Pipe Union

      Remove the 2 oil pipe unions, gaskets and No. 1 oil pipe.

    2. Remove the oil control valve filter LH and gaskets.

  9. REMOVE OIL PIPE


    1. A01HXF8E04
      Text in Illustration
      *1 Oil Pipe Union
      *2 Bolt

      Remove the bolt.

    2. Remove the 2 oil pipe unions and oil pipe.

    3. Remove the oil control valve filter RH and gaskets.

  10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

    A01HYWME07
    Text in Illustration
    *a for Bank 1
    *b for Bank 2

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

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

  11. REMOVE OIL FILTER CAP ASSEMBLY


    1. A01I24LE01
      Text in Illustration
      *1 Pipe
      *2 Hose

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

    2. A01HZWB

      Remove the oil filter drain plug from the oil filter cap.

    3. A01HZUEE02
      Text in Illustration
      *1 Cap
      *2 O-ring
      *3 Pipe

      Insert the pipe with the hose into the oil filter cap.

      Note

      Be sure to insert the pipe with the O-ring installed on the oil filter cap.

      Tech Tips

      Place the hose end into a container before draining oil from the hose.

    4. A01HZ0L

      Make sure that oil is completely drained, and remove the pipe and O-ring.

      Tech Tips

      Be sure to turn the pipe in the direction of the arrow to remove it.

    5. A01HXG7E01

      Using SST, remove the oil filter cap.

      SST
      09228-06501
    6. A01HZ70E06
      Text in Illustration
      *1 Oil Filter Element
      *2 Oil Filter Cap
      *3 O-ring

      Remove the oil filter element and O-ring from the oil filter cap.

      Note

      Do not use any tools to remove the O-ring in order to prevent the cap from being damaged. Be sure to remove it by hand.

  12. REMOVE CRANKSHAFT PULLEY


    1. A01HZITE03
      Text in Illustration
      *a Hold
      A01I0B8 Turn

      Using SST, loosen the crankshaft pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A01HZAXE01
      Text in Illustration
      *a Hold
      A01I0B8 Turn

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
    3. A01HXPI

      Remove the pulley set key from the crankshaft.

  13. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01HYP5

      Remove the bolt and engine oil level dipstick guide.

    2. A01I14H

      Remove the O-ring.

  14. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A01I19E

      Remove the 6 bolts and No. 1 front engine mounting bracket LH.

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

  15. REMOVE WATER INLET HOUSING


    1. A01HZ27

      Remove the 2 nuts, water inlet and thermostat.

    2. Remove the gasket.

    3. Remove the 2 stud bolts.

    4. Separate the No. 1 water by-pass hose from the water inlet housing.

    5. A01HXY1E04
      Text in Illustration
      *1 Nut
      *2 Bolt

      Remove the drain cock plug.

    6. Remove the drain cock assembly.

    7. Remove the 2 bolts, nut, and water inlet housing.

    8. A01I1U4

      Remove the 2 O-rings.

  16. REMOVE WATER OUTLET


    1. A01HYA7E02
      Text in Illustration
      *1 Nut
      *2 Bolt

      Remove the 2 bolts, 4 nuts and water outlet.

    2. A01I1RC

      Remove the 2 gaskets and O-ring.

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01HXF1

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

    2. A01I0B2

      Remove the 3 gaskets.

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01HXEHE05
      Text in Illustration
      *1 Baffle Plate

      Remove the 12 bolts, seal washer, cylinder head cover sub-assembly LH and No. 2 cylinder head cover gasket.

      Note

      The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the cylinder head cover sub-assembly LH.

    2. A01HXJZ

      Remove the 3 gaskets.

  19. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01I1PVE02
      Text in Illustration
      *1 Nut

      Remove the 16 bolts and 2 nuts.

    2. A01HY30

      Insert the blade of the oil pan seal 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.

    3. Using an E6 "TORX" socket wrench, remove the 2 stud bolts.

  20. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01HXHKE03
      Text in Illustration
      *1 Bolt
      *2 Nut

      Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.

    2. Using an E6 "TORX" socket wrench, remove the 2 stud bolts.

  21. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01HYTBE03
      Text in Illustration
      *1 Nut

      Remove the 16 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. A01I12IE02
      Text in Illustration
      *1 Protective Tape

      Remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly 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.

    3. A01I1FJ

      Remove the 2 O-rings.

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

  22. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01HY2R

      Remove the 7 bolts and No. 1 oil pan baffle plate.

  23. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01HZJI

      Remove the 6 bolts.

    2. A01I0H0E02
      Text in Illustration
      *1 Protective Tape
      A01I0B8 Pry

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

      Note

      Be careful not to damage the engine rear oil seal retainer.

      Tech Tips

      Tape the screwdriver tip before use.

  24. REMOVE ENGINE REAR OIL SEAL


    1. A01I1RKE07
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

      Place the engine rear oil seal retainer on wooden blocks.

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

      Note

      Be careful not to damage the engine rear oil seal retainer.

      Tech Tips

      Tape the screwdriver tip before use.

  25. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01I086

      Remove the 16 bolts, engine water pump assembly and water pump gasket.

  26. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01I1O2E02
      Text in Illustration
      *1 Nut

      Remove the 15 bolts and 2 nuts as shown in the illustration.

    2. A01I1I6E04
      Text in Illustration
      *1 Protective Tape

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

      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. Remove the 4 bolts, timing chain cover plate and timing chain cover plate gasket.

    4. A01HXFG

      Remove the gasket.

  27. REMOVE TIMING CHAIN CASE OIL SEAL


    1. A01HZJ4E05
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

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

      Tech Tips

      Tape the screwdriver tip before use.

  28. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily tighten the pulley set bolt.

    2. A01I1UXE02
      Text in Illustration
      *1 Sensor Plate
      *a Center Line
      *b Timing Mark

      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. A01HZM2E07
      Text in Illustration
      *a Timing Mark

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

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

  29. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01I0RME06
      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 1.27 mm diameter (0.0500 in.) into the stopper plate hole.

    3. A01HYJQ

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

  30. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  31. REMOVE CHAIN SUB-ASSEMBLY


    1. A01I1H3E02
      Text in Illustration
      *1 Sensor Plate
      *a Center Line
      *b Timing Mark

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

    2. Remove the pulley set bolt.

    3. A01HYCF

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

    4. A01I1H7E13
      Text in Illustration
      *a for Bank 1

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

    5. Remove the chain sub-assembly.

  32. REMOVE IDLE SPROCKET ASSEMBLY


    1. A01HZ1W

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

  33. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01I04N

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

  34. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. Remove the 2 No. 2 chain vibration dampers.

  35. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01HXTN

      Remove the crankshaft timing sprocket from the crankshaft.

    2. Remove the 2 keys from the crankshaft.

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


    1. A01HXR1E08
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

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

    2. A01HY78E06
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09922-10010

      Note


      • Be careful not to damage the cylinder head with SST.

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

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

  37. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01I09M

      Remove the bolt and No. 2 chain tensioner assembly.

  38. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A01HYBKE08
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A01I1DIE03

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

    3. A01HYMCE01

      Uniformly loosen and remove the 12 bearing cap bolts in several steps and in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 5 camshaft bearing caps.

  39. REMOVE CAMSHAFT


    1. Remove the camshaft.

  40. REMOVE NO. 2 CAMSHAFT


    1. Remove the No. 2 camshaft.

  41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01I17QE02
      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.

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


    1. A01HXSHE07
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

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

    2. A01HXE2E06
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09922-10010

      Note


      • Be careful not to damage the cylinder head with SST.

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

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

  43. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01HZV7

      Remove the bolt and No. 3 chain tensioner assembly.

  44. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A01HZNVE06
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A01HY6EE03

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

    3. A01I0P9E01

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

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 5 camshaft bearing caps.

  45. REMOVE NO. 3 CAMSHAFT


    1. Remove the No. 3 camshaft.

  46. REMOVE NO. 4 CAMSHAFT


    1. Remove the No. 4 camshaft.

  47. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01I18FE02
      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.

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


    1. Remove the 24 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  49. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 24 valve lash adjuster assemblies from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  50. REMOVE VALVE STEM CAP


    1. Remove the 24 valve stem caps.

  51. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH


    1. A01HY7QE01

      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 the incorrect order.

      Tech Tips

      Arrange the removed parts in the correct order.

    2. Remove the cylinder head sub-assembly RH.

  52. REMOVE CYLINDER HEAD GASKET RH


    1. Remove the cylinder head gasket RH.

  53. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. A01I12PE01

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

    2. A01I02JE01

      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 the incorrect order.

      Tech Tips

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

    3. Remove the cylinder head sub-assembly LH.

  54. REMOVE CYLINDER HEAD GASKET LH


    1. Remove the cylinder head gasket LH.

  55. REMOVE WATER INLET PIPE


    1. Remove the 2 clamps and separate the No. 1 water by-pass hose.

    2. A01HYV1

      Remove the 2 bolts and water inlet pipe.