ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap sub-assembly and oil filler cap gasket.

  2. REMOVE SPARK PLUG

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  3. REMOVE OIL PAN DRAIN PLUG


    1. A002AEA

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

  4. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A0029ZV

      Remove the ventilation valve sub-assembly.

  5. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side of Bank 1)

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  6. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side of Bank 1)

    Click here

  7. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side of Bank 2)

    Click here

  8. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side of Bank 2)

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

  13. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  14. REMOVE NO. 1 OIL PIPE


    1. A002986C01
      *a Oil Pipe Union

      Remove the 2 oil pipe unions, 3 gaskets and No. 1 oil pipe.

    2. Remove the oil control valve filter LH.

  15. REMOVE OIL PIPE


    1. A0028JJC07
      *a Oil Pipe Union
      *b Bolt

      Remove the bolt.

    2. Remove the 2 oil pipe unions, 3 gaskets and oil pipe.

    3. Remove the oil control valve filter RH.

  16. REMOVE TAPER SCREW PLUG

    Tech Tips

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


    1. A0026ZY

      Remove the taper screw plug from the cylinder block sub-assembly.

  17. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

    A002BENC01
    *A for Bank 1
    *B for Bank 2

    1. for Bank 1:


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

      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 cylinder block water drain cock sub-assembly is installed.


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

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

  18. REMOVE OIL FILTER CAP ASSEMBLY

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  19. REMOVE CRANKSHAFT PULLEY

    Click here

  20. REMOVE OIL COOLER ASSEMBLY

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  21. REMOVE NO. 1 OIL COOLER BRACKET


    1. A002BYH

      Remove the 3 bolts, 3 nuts, and oil cooler pipe with No. 1 oil cooler bracket and gasket.

    2. A002955C06
      *a Nut
      *b Bolt

      Remove the bolt, 2 nuts, No. 1 oil cooler bracket, and gasket.

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

    4. Using an E7 "TORX" socket wrench, remove the stud bolt.

  22. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A0028TG

      Remove the engine oil level dipstick guide.

    2. A0026U1

      Remove the O-ring.

  23. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A0027IK

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

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

  24. REMOVE WATER OUTLET


    1. A00279IC02
      *a Nut
      *b Bolt

      Remove the 2 bolts, 4 nuts and water outlet.

    2. A002CAC

      Remove the 2 gaskets and O-ring.

  25. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A0027HWC06
      *1 Seal Washer

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

    2. A0028Z8

      Remove the 3 gaskets.

  26. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A002C0XC01
      *1 Seal Washer
      *a 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. A0027B3

      Remove the 3 gaskets.

  27. REMOVE WATER INLET HOUSING


    1. A00274O

      Remove the 2 nuts, water inlet and thermostat.

    2. Remove the gasket.

    3. Remove the 2 stud bolts.

    4. Disconnect the No. 1 water by-pass hose from the water inlet housing.

    5. A00298GC07
      *a Nut
      *b Bolt

      Remove the drain cock plug.

    6. Remove the drain cock assembly.

    7. Remove the 2 bolts, nut, and water inlet housing.

    8. A0027V1

      Remove the 2 O-rings.

  28. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A002C0BC06
      *a Nut

      Remove the 16 bolts and 2 nuts.

    2. B003Z3Q

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and No. 2 oil pan sub-assembly. 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 from the oil pan sub-assembly.

  29. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A0029HMC07
      *a Bolt
      *b Nut

      Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.

    2. Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the oil pan sub-assembly.

  30. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the oil pan sub-assembly.

      Click here

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

      A0029EQC01
      *A Type A *B Type B
      *a Timing Chain Cover Sub-assembly Side *b Cylinder Block Sub-assembly Bottom Side
      *c Oil Pan Sub-assembly LH Side - -

  31. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A00286N

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

  32. REMOVE REAR ENGINE OIL SEAL RETAINER


    1. A002BLZ

      Remove the 6 bolts.

    2. A002884C06
      *a Protective Tape
      B003ZIE 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.

  33. REMOVE REAR ENGINE OIL SEAL


    1. A002A3AC04
      *a Protective Tape
      *b Wooden Block

      Place the rear engine oil seal retainer on wooden blocks.

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  34. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

  35. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A002AC9C03
      *a Nut

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

    2. A002B4VC06
      *a 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 sub-assembly with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder head sub-assembly, cylinder block sub-assembly 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. A002C36

      Remove the gasket.

  36. REMOVE TIMING CHAIN CASE OIL SEAL

    Click here

  37. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily tighten the crankshaft pulley bolt.

    2. A0028E6C10
      *a Sensor Plate
      *b Center Line
      *c Timing Mark

      Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the center line of the block bore (Bank 1) (TDC/compression).

    3. A002B3TC02
      *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 aligned, turn the crankshaft 1 revolution (360°) clockwise and align the timing marks as above.

  38. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A00292RC12
      *a Plunger
      *b Stopper Plate
      *c Hexagon Wrench

      Turn the stopper plate clockwise to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.

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

    3. A0028AK

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

  39. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  40. REMOVE CHAIN SUB-ASSEMBLY


    1. A0028CHC05
      *a Sensor Plate
      *b Center Line
      *c Timing Mark

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

    2. Remove the crankshaft pulley bolt.

    3. A002AGO

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

    4. A002BRGC01
      *A for Bank 1

      Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) and set it as shown in the illustration.

      Note

      Be sure to loosen the chain sub-assembly between the banks.

    5. Remove the chain sub-assembly.

  41. REMOVE IDLE SPROCKET ASSEMBLY


    1. A002ANJ

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

  42. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A0028K3

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

  43. REMOVE NO. 2 CHAIN VIBRATION DAMPER


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

  44. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A002B57

      Remove the crankshaft timing sprocket from the crankshaft.

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

  45. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)

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  46. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

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  47. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

    Click here

  48. REMOVE CAMSHAFT

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  49. REMOVE NO. 2 CAMSHAFT

    Click here

  50. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

    Click here

  51. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)

    Click here

  52. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

    Click here

  53. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

    Click here

  54. REMOVE NO. 3 CAMSHAFT

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  55. REMOVE NO. 4 CAMSHAFT

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  56. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

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

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  58. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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  59. REMOVE VALVE STEM CAP

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  60. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

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  61. REMOVE CYLINDER HEAD GASKET RH

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  62. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

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  63. REMOVE CYLINDER HEAD GASKET LH

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  64. REMOVE WATER INLET PIPE


    1. Slide the clip and disconnect the No. 1 water by-pass hose from the water inlet pipe.

    2. A002C08

      Remove the 2 bolts and water inlet pipe.