ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap and gasket.

  2. REMOVE RADIATOR CAP SUB-ASSEMBLY

  3. REMOVE SPARK PLUG

    Click here

  4. REMOVE OIL PAN DRAIN PLUG


    1. Remove the drain plug and gasket.

  5. REMOVE PCV VALVE SUB-ASSEMBLY

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  6. DISCONNECT NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  7. REMOVE WATER BY-PASS HOSE ASSEMBLY

  8. REMOVE NO. 2 SEPARATOR CASE


    1. A000SHK

      Remove the 2 nuts, No. 2 separator case and O-ring.

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

  17. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  18. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A000QOT

      LH side:

      Remove the cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.

    2. A000RGT

      RH side:

      Remove the cylinder block water drain cock plug from the cylinder block water drain cock sub-assembly.

    3. Using a deep socket wrench (14 mm), remove the cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.

  19. REMOVE OIL FILTER ELEMENT

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  20. REMOVE CRANKSHAFT PULLEY

    Click here

  21. REMOVE WATER INLET SUB-ASSEMBLY


    1. A000O9D

      Separate the 3 water by-pass hoses.

    2. A000OR8

      Remove the 4 bolts, nut and water inlet.

    3. A000ON3

      Remove the 2 O-rings.

    4. A000Q32

      Remove the 3 water by-pass hoses.

  22. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY


    1. A000OIQ

      Remove the 3 nuts and water inlet with thermostat.

    2. Remove the gasket from the water inlet.

  23. REMOVE REAR WATER BY-PASS JOINT


    1. A000MZ2

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

    2. A000T08

      Remove the 2 gaskets and O-ring.

  24. REMOVE FUEL PUMP SPACER GASKET


    1. Remove the fuel pump spacer gasket from the cylinder head cover.

  25. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  26. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

    Click here

  27. REMOVE SPARK PLUG TUBE GASKET


    1. A000RE1E03
      Text in Illustration
      *1 Claw

      Pry up the claws of the ventilation baffle plate.

      Note

      Do not deform the claws of the baffle plate more than necessary.

    2. A000P8D

      Using a screwdriver as shown in the illustration, deform each spark plug tube gasket inwards and remove the 6 spark plug tube gaskets from the cylinder head cover.

      Note


      • As much as possible prevent the plug tube gaskets from being deformed. The removed gaskets will be used when reinstalling the gaskets.

      • Do not damage the connection of the cylinder head cover.

      • Make sure not to damage the spark plug tube gasket and cylinder head cover when inserting the screwdriver in the joint area.

      Tech Tips

      If the cylinder head cover is damaged, smooth the surface with 400-grit sandpaper.

  28. REMOVE OIL PAN DRAIN PLUG


    1. Remove the oil pan drain plug and gasket.

  29. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A000N2C

      Remove the 15 bolts and 2 nuts.

      Text in Illustration
      B002B6O Bolt
      B002BBR Nut
    2. A000T4M

      Insert the blade of an 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.

  30. REMOVE OIL PAN SUB-ASSEMBLY


    1. A000SSH

      Remove the 16 bolts and 2 nuts.

      Text in Illustration
      B002B6O Bolt
      B002BBR Nut

      Tech Tips

      Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

    2. A000N16E01
      Text in Illustration
      *a LH Side
      *b 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.

    3. A000NW1

      Remove the 2 O-rings.

  31. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A000P3D

      Remove the 3 nuts, oil strainer and gasket.

    2. A000SX9

      Remove the 8 bolts and baffle plate.

  32. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A000P67

      Remove the 6 bolts.

    2. A000PAX

      Using a screwdriver, pry out the oil seal retainer.

      Text in Illustration
      B002B6O Pry

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  33. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A000P72E06
      Text in Illustration
      *1 Wooden Block
      *2 Protective Tape

      Place the oil seal retainer on wooden blocks.

      Note

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

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

      Tech Tips

      Tape the screwdriver tip before use.

  34. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  35. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

  36. REMOVE TIMING CHAIN CASE OIL SEAL

    Click here

  37. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the pulley set bolt.

    2. A000P94E04
      Text in Illustration
      *1 Timing Mark
      *a Center Line

      Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC/compression).

    3. A000PJJE02
      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 cap as shown in the illustration.

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

  38. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A000O1OE20
      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 (0.0500 in.) diameter into the stopper plate's hole.

    3. A000NW6

      Remove the 2 bolts and chain tensioner.

  39. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  40. REMOVE CHAIN SUB-ASSEMBLY


    1. A000Q0EE04
      Text in Illustration
      *1 Timing Mark
      *a Center Line

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

    2. Remove the pulley set bolt.

    3. A000N3I

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

    4. A000REBE01
      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 between the banks.

    5. Remove the chain.

  41. REMOVE IDLE SPROCKET ASSEMBLY


    1. A000NJ9

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

  42. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A000SLZ

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

  43. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A000P60

      Remove the 2 No. 2 chain vibration dampers.

  44. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A000RTA

      Remove the crankshaft timing sprocket from the crankshaft.

    2. Remove the 2 pulley set keys from the crankshaft.

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

    Click here

  46. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

    Click here

  47. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

    Click here

  48. REMOVE FUEL PUMP LIFTER HOUSING

    Click here

  49. REMOVE CAMSHAFT

  50. REMOVE NO. 2 CAMSHAFT

  51. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

    Click here

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

    Click here

  53. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

    Click here

  54. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

    Click here

  55. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

  56. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

  57. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

    Click here

  58. REMOVE OIL CONTROL VALVE FILTER LH


    1. A000T45

      Remove the oil control valve filter LH from the camshaft bearing cap.

  59. REMOVE OIL CONTROL VALVE FILTER RH


    1. Remove the oil control valve filter RH from the camshaft bearing cap.

  60. REMOVE OIL CHECK VALVE


    1. A000QOY

      Remove the oil check valve from the camshaft bearing cap.

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

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  62. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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  63. REMOVE VALVE STEM CAP

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  64. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  65. REMOVE CYLINDER HEAD GASKET

  66. REMOVE CYLINDER HEAD LH

    Click here

  67. REMOVE NO. 2 CYLINDER HEAD GASKET

  68. REMOVE NO. 5 ENGINE WIRE


    1. A000RS4

      Detach the clamp and remove the No. 5 engine wire.

  69. REMOVE KNOCK SENSOR

    Click here

  70. REMOVE WATER OUTLET PIPE SUB-ASSEMBLY


    1. A000QC5

      Remove the 2 bolts and water outlet pipe.

  71. REMOVE NO. 1 STRAIGHT PIN

    Note

    It is not necessary to remove a No. 1 straight pin unless it is being replaced.

  72. REMOVE RING PIN

    Note

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