ENGINE UNIT DISASSEMBLY

CAUTION / NOTICE / HINT

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.

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  2. REMOVE OIL FILLER CAP HOUSING


    1. A000ZZ9

      Remove the 2 bolts, filler cap housing and gasket.

  3. REMOVE SPARK PLUG

    Click here

  4. REMOVE VVT SENSOR


    1. A000VSN

      for Bank 1:

      Remove the 2 bolts and 2 VVT sensors.

    2. A000WQC

      for Bank 2:

      Remove the 2 bolts and 2 VVT sensors.

  5. REMOVE CAMSHAFT POSITION SENSOR


    1. A000U26

      Remove the bolt and camshaft position sensor.

  6. REMOVE CRANKSHAFT POSITION SENSOR


    1. A000ZGB

      Remove the bolt and crankshaft position sensor.

  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A000TRO

      for Bank 1:

      Remove the bolt and oil control valve.

      Remove the O-ring from the valve.

    2. A000W83

      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. A000UVNE01
      *1 for RH:
      *2 for LH:

      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

    Click here

  10. REMOVE CAMSHAFT TIMING CONTROL WITH EDU MOTOR ASSEMBLY RH

    Click here

  11. REMOVE WIRE HARNESS CLAMP BRACKET

    A000W17

    1. Remove the bolt and wire harness clamp bracket.

  12. REMOVE OIL FILTER ELEMENT

    Click here

  13. REMOVE OIL FILTER BRACKET

    Click here

  14. REMOVE WATER PUMP PULLEY

    Click here

  15. REMOVE FRONT WATER BY-PASS JOINT


    1. A000X3Y

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

  16. REMOVE SPARK PLUG TUBE GASKET


    1. A000Y9IE03
      *1 Keyway Part

      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. A000WW4E09
      *a Fuel Pump Spacer Gasket

      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. A000TBS

      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. A000YCME08
      *a Fuel Pump Spacer Gasket

      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. A000ZL2

      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. A000XBWE05
        *1 Filter
        *2 Gasket
        *3 Cylinder Head Cover Spacer

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

    2. for RH:


      1. A000WFOE05
        *1 Filter
        *2 Gasket
        *3 Cylinder Head Cover Spacer

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

  20. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  21. REMOVE CRANKSHAFT PULLEY

    Click here

  22. REMOVE WATER PUMP

    Click here

  23. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  24. REMOVE WATER INLET PIPE

    Click here

  25. REMOVE FRONT CRANKSHAFT OIL SEAL

    A000X03

    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.

      A000TDGE03

  27. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH


    1. A000W05E03
      *1 Plunger
      *2 Stopper Plate

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

    2. A000VVLE03
      *1 Plunger
      *2 Stopper Plate

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

    3. A000WTA

      Remove the 2 bolts, chain tensioner and gasket.

  28. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

  29. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH

    A000Y8W

    Remove the 2 bolts and chain vibration damper.

  30. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH


    1. A000V33E06
      *1 Push
      *2 Pin
      *3 Plunger

      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. A000VYOE03
      *1 Turn
      *2 Hold

      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. A000VK8E03
      *1 Turn
      *2 Hold

      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. A000YLT

      Remove the 2 bolts and chain tensioner.

  32. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH


    1. A000TOYE03
      *1 Plunger
      *2 Stopper Plate

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

    2. A000YMDE03
      *1 Plunger
      *2 Stopper Plate

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

    3. A000XRC

      Remove the 2 bolts and chain tensioner.

  33. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

  34. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH


    1. A000ZZK

      Remove the 2 bolts and vibration damper.

  35. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH


    1. A000W91E05
      *1 Push
      *2 Pin
      *3 Plunger

      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. A000YTJE03
      *1 Hold
      *2 Turn

      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. A000YNTE03
      *1 Hold
      *2 Turn

      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. A000VAP

      Remove the 2 bolts and chain tensioner.

  37. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A000VFZ

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

  38. REMOVE CAMSHAFT BEARING CAP LH

    Click here

  39. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

    Click here

  40. REMOVE CAMSHAFT BEARING CAP RH

    Click here

  41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

    Click here

  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

    Click here

  46. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

    Click here

  47. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A000WBL

      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

    A000XJI

    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

    A000UEP

    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. A000XZME04
      *1 Nut

      Remove the 11 bolts and 2 nuts.

    2. A000VQI

      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. A000V2U

      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. A000ZLIE04
      *1 Nut

      Remove the 13 bolts and 2 nuts.

    2. A000YGP

      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. A000TRGE05
      *1 Nut

      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. A000Z1CE03
      *1 LH Side:
      *2 RH Side:

      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. A000V8T

      Remove the 4 bolts and baffle plate.

  55. REMOVE NO. 2 OIL PAN BAFFLE PLATE


    1. A000Z70

      Remove the 4 bolts and baffle plate.

  56. REMOVE ENGINE OIL LEVEL SENSOR

    Click here

  57. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A000U1F

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

  58. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A000Y25

      Remove the 6 bolts.

    2. A000VIL

      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. A000VIM

      Remove the bolt and oil drain pipe.

    2. Remove the O-ring.

  60. REMOVE NO. 1 VENTILATION CONNECTOR


    1. A000W2JE03
      *1 Front

      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

    A000ZPZE02
    *1 Wooden Block

    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.