ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE SPARK PLUG

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  2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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  3. REMOVE NO. 1 FUEL TUBE SUB-ASSEMBLY

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  4. REMOVE VENTILATION HOSE ASSEMBLY


    1. B003V52

      Loosen the hose clamp and remove the ventilation hose assembly from the cylinder head cover sub-assembly LH.

  5. REMOVE VENTILATION VALVE SUB-ASSEMBLY

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

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

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

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

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  10. REMOVE CRANKSHAFT POSITION SENSOR

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  11. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. B003SZT

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

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

  12. REMOVE CYLINDER BLOCK WATER DRAIN COCK PLUG


    1. B003V14

      Remove the cylinder block water drain cock plug from the cylinder block.

  13. REMOVE OIL FILTER CAP ASSEMBLY

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  14. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

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  15. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler)

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  16. REMOVE CRANKSHAFT PULLEY

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  17. REMOVE WATER OUTLET SUB-ASSEMBLY


    1. B003U5U

      Remove the 2 bolts and water outlet sub-assembly.

    2. B003VJ2

      Remove the O-ring from the No. 1 water outlet pipe.

  18. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY


    1. B003TFUC02
      B003WAF Bolt
      B003U82 Nut

      Remove the 2 bolts, nut, water inlet with thermostat sub-assembly and water inlet housing gasket.

  19. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)

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  20. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)

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  21. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)

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  22. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)

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  23. REMOVE REAR WATER BY-PASS JOINT


    1. B003TCV

      Disengage the 2 clamps and disconnect the No. 5 engine wire from the rear water by-pass joint.

    2. B003UJ0C02
      B003WAF Bolt
      B003U82 Nut

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

    3. B003VFD

      Remove the 2 water by-pass joint gaskets from the rear water by-pass joint.

    4. B003UXJ

      Remove the O-ring from the No. 1 water outlet pipe.

  24. REMOVE VACUUM PUMP ASSEMBLY

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  25. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  26. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

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  27. REMOVE SPARK PLUG TUBE GASKET


    1. B003VTO

      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.

  28. REMOVE OIL PAN DRAIN PLUG


    1. Remove the oil pan drain plug and gasket.

  29. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

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  30. REMOVE ENGINE OIL LEVEL SENSOR

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  31. REMOVE OIL LEVEL SENSOR BRACKET

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  32. REMOVE OIL PAN SUB-ASSEMBLY

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  33. REMOVE OIL STRAINER SUB-ASSEMBLY

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  34. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. B003UMF

      Remove the 8 bolts and No. 1 oil pan baffle plate.

  35. REMOVE REAR ENGINE OIL SEAL RETAINER


    1. B003TCW

      Remove the 6 bolts.

    2. B003W1HC02
      B003WAF Pry

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  36. REMOVE REAR ENGINE OIL SEAL


    1. B003U9BC04
      *a Wooden Block
      *b Protective Tape

      Place the rear engine oil seal retainer on wooden blocks.

      Note

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

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

      Tech Tips

      Tape the screwdriver tip before use.

  37. REMOVE TIMING CHAIN COVER PLATE

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  38. REMOVE TIMING CHAIN COVER ASSEMBLY

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  39. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. B003VR0

      Remove the 7 bolts and engine water pump assembly.

    2. Remove the water pump gasket.

  40. REMOVE TIMING CHAIN CASE OIL SEAL

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  41. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley set bolt.

    2. B003TZNC06
      *1 Timing Gear Set Key
      *a Center Mark

      Set the timing gear set key to the RH block bore center mark (TDC/compression).

    3. B003VWNC04
      *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 1 revolution (360°) and align the timing marks as described above.

  42. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B003T51C26
      *a Plunger
      *b Stopper Plate
      *c 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 (0.0500 in.) diameter into the stopper plate's hole.

    3. B003W96

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

  43. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  44. REMOVE CHAIN SUB-ASSEMBLY


    1. B003X5ZC02
      *1 Timing Gear Set Key
      *a Timing Mark
      *b Center Line
      *c 10°

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

    2. Remove the pulley set bolt.

    3. B003TJM

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

    4. B003T49C02
      *A for Bank 1
      *a Flat Surface

      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.

      Tech Tips

      The flat surface on the camshaft timing exhaust gear assembly must be positioned as shown in the illustration.

    5. Remove the chain sub-assembly.

  45. REMOVE IDLE SPROCKET ASSEMBLY


    1. B003UTF

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

  46. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B003WMB

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

  47. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. B003VRE

      Remove the 2 No. 2 chain vibration dampers.

  48. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET


    1. B003WP5

      Remove the crankshaft timing gear or sprocket from the crankshaft.

    2. Remove the 2 timing gear set keys from the crankshaft.

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

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  50. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

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  51. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

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  52. REMOVE FUEL PUMP LIFTER HOUSING

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  53. REMOVE CAMSHAFT

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  54. REMOVE NO. 2 CAMSHAFT

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  55. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

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

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  57. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

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  58. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

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  59. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

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  60. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

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  61. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

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  62. REMOVE OIL CONTROL VALVE FILTER (for Bank 1)


    1. B003UBN

      Remove the 2 oil control valve filters from the No. 1 and No. 2 camshaft bearing caps.

  63. REMOVE OIL CONTROL VALVE FILTER (for Bank 2)


    1. Remove the oil 2 control valve filters from the No. 3 and No. 4 camshaft bearing caps.

  64. REMOVE CAMSHAFT BEARING CAP OIL HOLE GASKET RH


    1. B003U3Q

      Remove the camshaft bearing cap oil hole gasket RH from the No. 7 camshaft bearing cap.

  65. REMOVE CAMSHAFT BEARING CAP OIL HOLE GASKET LH


    1. B003UHX

      Remove the camshaft bearing cap oil hole gasket LH from the No. 6 camshaft bearing cap.

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

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  67. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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  68. REMOVE VALVE STEM CAP

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  69. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  70. REMOVE CYLINDER HEAD GASKET

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  71. REMOVE CYLINDER HEAD LH

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  72. REMOVE NO. 2 CYLINDER HEAD GASKET

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  73. REMOVE NO. 5 ENGINE WIRE


    1. B003WGX

      Detach the 2 clamps, 2 connector and remove the No. 5 engine wire.

  74. REMOVE KNOCK CONTROL SENSOR

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  75. REMOVE NO. 1 WATER OUTLET PIPE


    1. B003T47

      Remove the 2 bolts and No. 1 water outlet pipe.

  76. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. B003UDJ

      Remove the 2 cylinder block water jacket spacers from the cylinder block.

      Note

      Be sure to remove the cylinder block water jacket spacers. If not, they may fall and become damaged when the cylinder block is inverted.

  77. REMOVE STRAIGHT PIN

    Note

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

  78. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

    Note

    It is not necessary to remove a camshaft bearing cap setting ring pin unless it is being replaced.