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. B000HV3

      Remove the 6 spark plugs.

  3. REMOVE OIL PAN DRAIN PLUG


    1. B000KSP

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

  4. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. B000NDF

      Remove the ventilation valve sub-assembly.

  5. REMOVE VVT SENSOR


    1. Disconnect the 4 sensor connectors.

    2. B000H4UE02
      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. B000NLRE01
      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. B000MYOE06
      Text in Illustration
      *1 O-ring

      Remove the O-ring from each oil control valve.

  7. REMOVE CRANK POSITION SENSOR


    1. B000KHC

      Disconnect the crank position sensor connector.

    2. Remove the bolt and crank position sensor.

  8. REMOVE NO. 1 OIL PIPE


    1. B000JTQE02
      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. B000MCYE04
      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 TAPER SCREW PLUG

    B000MTY

    Tech Tips

    Perform this operation only when a taper screw plug is installed.


    1. Remove the taper screw plug from the cylinder block.

  11. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. for Bank 1:


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

      2. B000KWNE01
        Text in Illustration
        *a for Bank 1
        *b for Bank 2

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

    2. for Bank 2:

      Tech Tips

      Perform this operation only when a taper screw plug is not installed.

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

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

  12. REMOVE OIL FILTER CAP ASSEMBLY


    1. B000I74E01
      Text in Illustration
      *1 Pipe
      *2 Hose

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

    2. B000LSJ

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

    3. B000NG9E02
      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. B000HTJ

      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. B000M5DE01

      Using SST, remove the oil filter cap.

      SST
      09228-06501
    6. B000LWPE06
      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.

  13. REMOVE CRANKSHAFT PULLEY


    1. B000KEPE03
      Text in Illustration
      *a Hold
      B000K70 Turn

      Using SST, loosen the crankshaft pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. B000HLRE01
      Text in Illustration
      *a Hold
      B000K70 Turn

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
    3. B000L5G

      Remove the pulley set key from the crankshaft.

  14. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. B000IN5

      Remove the bolt and engine oil level dipstick guide.

    2. B000JNJ

      Remove the O-ring.

  15. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. B000IK3

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

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

  16. REMOVE WATER INLET HOUSING


    1. B000NGU

      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. B000MBVE04
      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. B000ICE

      Remove the 2 O-rings.

  17. REMOVE WATER OUTLET


    1. B000KDCE02
      Text in Illustration
      *1 Nut
      *2 Bolt

      Remove the 2 bolts, 4 nuts and water outlet.

    2. B000NE6

      Remove the 2 gaskets and O-ring.

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B000M36

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

    2. B000IQR

      Remove the 3 gaskets.

  19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. B000I2HE05
      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. B000KN0

      Remove the 3 gaskets.

  20. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. B000NKTE02
      Text in Illustration
      *1 Nut

      Remove the 16 bolts and 2 nuts.

    2. B000HY8

      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.

  21. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B000H7WE03
      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.

  22. REMOVE OIL PAN SUB-ASSEMBLY


    1. B000KH9E01
      Text in Illustration
      *A Type A
      *B Type B
      *a 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. B000H1SE02
      Text in Illustration
      *1 Protective Tape

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

      Note

      Be careful not to damage the contact surfaces of the cylinder block and oil pan sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    3. B000N4J

      Remove the 2 O-rings.

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

  23. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. B000I05

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

  24. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. B000MJN

      Remove the 6 bolts.

    2. B000KGME02
      Text in Illustration
      *1 Protective Tape
      B000K70 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.

  25. REMOVE ENGINE REAR OIL SEAL


    1. B000NGEE07
      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 engine rear oil seal.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  26. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. B000KQE

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

  27. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. B000MOVE02
      Text in Illustration
      *1 Nut

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

    2. B000HADE04
      Text in Illustration
      *1 Protective Tape

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

      Note

      Be careful not to damage the contact surfaces of the cylinder head sub-assembly, cylinder block and timing chain cover sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

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

    4. B000LUY

      Remove the gasket.

  28. REMOVE TIMING CHAIN CASE OIL SEAL


    1. B000HJTE05
      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.

  29. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily tighten the pulley set bolt.

    2. B000N77E02
      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. B000LSOE07
      Text in Illustration
      *a Timing Mark

      Check that the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are aligned with the timing marks of the camshaft bearing caps as shown in the illustration.

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

  30. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B000IOKE06
      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 No. 1 chain tensioner assembly.

    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. B000HC6

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

  31. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  32. REMOVE CHAIN SUB-ASSEMBLY


    1. B000JKEE02
      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. B000I6F

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

    4. B000H12E13
      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.

  33. REMOVE IDLE SPROCKET ASSEMBLY


    1. B000I9J

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

  34. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B000LPB

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

  35. REMOVE NO. 2 CHAIN VIBRATION DAMPER


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

  36. REMOVE CRANKSHAFT TIMING SPROCKET


    1. B000IJN

      Remove the crankshaft timing sprocket from the crankshaft.

    2. Remove the 2 keys from the crankshaft.

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


    1. B000HQ1E08
      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. B000HTNE06
      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.

  38. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B000MED

      Remove the bolt and No. 2 chain tensioner assembly.

  39. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. B000JF7E08
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. B000MAAE03

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

    3. B000JM0E01

      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.

  40. REMOVE CAMSHAFT


    1. Remove the camshaft.

  41. REMOVE NO. 2 CAMSHAFT


    1. Remove the No. 2 camshaft.

  42. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. B000J0DE02
      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.

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


    1. B000HX3E07
      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. B000MJOE06
      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.

  44. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B000NS7

      Remove the bolt and No. 3 chain tensioner assembly.

  45. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. B000MI5E06
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. B000IQJE03

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

    3. B000LVSE01

      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.

  46. REMOVE NO. 3 CAMSHAFT


    1. Remove the No. 3 camshaft.

  47. REMOVE NO. 4 CAMSHAFT


    1. Remove the No. 4 camshaft.

  48. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. B000KZGE02
      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.

  49. 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.

  50. 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.

  51. REMOVE VALVE STEM CAP


    1. Remove the valve stem caps from the cylinder heads.

      Tech Tips

      Arrange the removed parts in the correct order.

  52. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH


    1. B000NBQE01

      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.

  53. REMOVE CYLINDER HEAD GASKET RH


    1. Remove the cylinder head gasket RH.

  54. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. B000H51E01

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

    2. B000J3SE01

      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.

  55. REMOVE CYLINDER HEAD GASKET LH


    1. Remove the cylinder head gasket LH.

  56. REMOVE WATER INLET PIPE


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

    2. B000LI8

      Remove the 2 bolts and water inlet pipe.