ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01XJBW

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

  2. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A01XMI7

      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. A01XGY4

      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. A01XHR7

      LH:

      Remove the 2 bolts and 2 VVT sensors.

    2. A01XHFT

      RH:

      Remove the 2 bolts and 2 VVT sensors.

  5. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01XCLP

      Remove the bolt and crankshaft position sensor.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH


    1. A01XHAQ

      LH:

      Remove the 2 bolts and 2 oil control valves.

    2. A01XDDH

      RH:

      Remove the 2 bolts and 2 oil control valves.

  7. REMOVE OIL FILLER CAP HOUSING


    1. A01XK9J

      Remove the oil filler cap.

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

  8. REMOVE NO. 1 OIL PIPE

    Click here

  9. REMOVE NO. 2 OIL PIPE

    Click here

  10. REMOVE OIL FILTER ELEMENT

    Click here

  11. REMOVE OIL FILTER BRACKET

    Click here

  12. REMOVE WATER INLET HOUSING

    Click here

  13. REMOVE REAR WATER BY-PASS JOINT


    1. A01XGA5

      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

    Click here

  15. REMOVE PCV VALVE SUB-ASSEMBLY


    1. Remove the PCV valve hose.

    2. A01XI6B

      Remove the PCV valve.

  16. REMOVE CRANKSHAFT PULLEY

    Click here

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01XFTU

      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. B001ENF

      Remove the 3 gaskets.

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01XEYU

      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. A01XI7K

      Remove the 3 gaskets.

  19. REMOVE SPARK PLUG TUBE GASKET

    A01XHQP

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

      Text in Illustration
      B001CHY 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)

    Click here

  21. REMOVE OIL PAN DRAIN PLUG


    1. Remove the drain plug and gasket.

  22. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  23. REMOVE OIL STRAINER SUB-ASSEMBLY

    Click here

  24. REMOVE OIL PAN SUB-ASSEMBLY

    Click here

  25. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01XMQ5

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

  26. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01XKPWE09
      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. A01XIZN

      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

    Click here

  29. REMOVE WATER PUMP ASSEMBLY


    1. A01XIZ2

      Remove the 8 bolts, water pump and gasket.

  30. REMOVE FRONT CRANKSHAFT OIL SEAL

    Click here

  31. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the pulley set bolt.

    2. A01XJEGE05
      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. A01XI6NE01
      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. A01XGYJE21
      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. A01XHXK

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

  33. REMOVE CHAIN TENSIONER SLIPPER


    1. A01XIMZ

      Remove the chain tensioner slipper.

  34. REMOVE NO. 1 CHAIN SUB-ASSEMBLY


    1. A01XMP3E05
      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. A01XHGJ

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

    4. A01XE2BE01

      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. A01XE2F

      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. A01XIH7

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

  37. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A01XHS6

      Remove the 2 No. 2 chain vibration dampers.

  38. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01XFSA

      Remove the crankshaft timing sprocket.

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


    1. A01XL2TE05
      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. A01XCT9E01
      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. A01XJF0

      Remove the bolt and No. 2 chain tensioner assembly.

  41. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A01XHF5E06
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A01XHDKE09

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

    3. A01XIY1E05

      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. A01XMOHE05
      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. A01XM0TE07
      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. A01XETME09
      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. A01XJ5U

      Remove the bolt and No. 3 chain tensioner assembly.

  45. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A01XKW0E05
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A01XLKDE09

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

    3. A01XIS1E05

      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. A01XIWUE05
      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

    Click here

  51. REMOVE CYLINDER HEAD LH

    Click here

  52. REMOVE CYLINDER HEAD GASKET

  53. REMOVE NO. 2 CYLINDER HEAD GASKET

  54. REMOVE NO. 1 WATER OUTLET PIPE

    Click here

  55. REMOVE KNOCK SENSOR

    Click here

  56. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    A01XLBZ

    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.