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ENGINE UNIT DISASSEMBLY

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PROCEDURE


  1. Click here

    REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap sub-assembly from the oil filler cap housing.

    2. Remove the oil filler cap gasket from the oil filler cap sub-assembly.

  2. Click here

    REMOVE OIL FILLER CAP HOUSING


    1. B0065KX

      Remove the 2 bolts, oil filler cap housing and oil filler cap housing gasket.

  3. Click here

    REMOVE SPARK PLUG

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  4. Click here

    REMOVE OIL PAN DRAIN PLUG


    1. Remove the oil pan drain plug and gasket from the No. 2 oil pan sub-assembly.

  5. Click here

    REMOVE VVT SENSOR (for Exhaust Side of Bank 1)

    Click here

  6. Click here

    REMOVE VVT SENSOR (for Exhaust Side of Bank 2)

    Click here

  7. Click here

    REMOVE VVT SENSOR (for Intake Side of Bank 1)

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  8. Click here

    REMOVE VVT SENSOR (for Intake Side of Bank 2)

    Click here

  9. Click here

    REMOVE CAMSHAFT POSITION SENSOR

    Click here

  10. Click here

    REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  11. Click here

    REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY LH

    Click here

  12. Click here

    REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH

    Click here

  13. Click here

    REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. B0067HZC01
      *A for Bank 1
      *B for Bank 2

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

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

  14. Click here

    REMOVE CAMSHAFT TIMING CONTROL MOTOR WITH EDU ASSEMBLY LH

    Click here

  15. Click here

    REMOVE CAMSHAFT TIMING CONTROL MOTOR WITH EDU ASSEMBLY RH

    Click here

  16. Click here

    REMOVE FRONT WATER BY-PASS JOINT


    1. B0067TY

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

  17. Click here

    REMOVE OIL FILTER CAP ASSEMBLY


    1. B0067MSC02
      *a Cap Rib

      Using SST, loosen the oil filter cap assembly 4 turns, align the cap ribs vertically, and drain the remaining engine oil from the oil filter cap assembly.

      09228-06501
      Tip:

      Set a container below the oil filter cap assembly before loosening the oil filter cap assembly.

    2. Remove the oil filter cap assembly.

    3. B0067RVC03
      *1 Oil Filter Element
      *2 Oil Filter Cap Assembly
      *3 O-ring

      Remove the oil filter element and O-ring from the oil filter cap assembly.

      Note:

      Do not use any tools to remove the O-ring in order to prevent the oil filter cap assembly from being damaged. Be sure to remove it by hand.

  18. Click here

    REMOVE OIL THERMOSTAT HOUSING ASSEMBLY

    Click here

  19. Click here

    REMOVE OIL FILTER BRACKET


    1. B0065U5

      Remove the 2 bolts and oil filter bracket stay.

    2. B006867

      Remove the 2 bolts, 2 nuts and oil filter bracket.

    3. Remove the 2 gaskets from the timing chain cover assembly.

  20. Click here

    REMOVE CRANKSHAFT PULLEY

    Click here

  21. Click here

    REMOVE NO. 1 V-BANK COVER BRACKET (for Bank 1)


    1. B0067C0

      Remove the No. 1 V-bank cover bracket from the cylinder head cover sub-assembly LH.

  22. Click here

    REMOVE NO. 1 V-BANK COVER BRACKET (for Bank 2)


    1. B0065CK

      Remove the No. 1 V-bank cover bracket from the cylinder head cover sub-assembly.

  23. Click here

    REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. B0067P5

      Remove the fuel pump spacer gasket.

    2. Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly LH and cylinder head cover gasket LH.

      Tip:

      Arrange the removed parts in such a way that they can be installed to their original locations.

    3. B0067LF

      Remove the 2 oil hole gaskets and 2 O-rings from the camshaft bearing caps.

  24. Click here

    REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B0067W6

      Remove the fuel pump spacer gasket.

    2. Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.

      Tip:

      Arrange the removed parts in such a way that they can be installed to their original locations.

    3. B00688V

      Remove the 2 oil hole gaskets and 2 O-rings from the camshaft bearing caps.

  25. Click here

    REMOVE SPARK PLUG TUBE GASKET


    1. B0066S5

      Using a screwdriver, pry out the 8 spark plug tube gaskets from each cylinder head sub-assembly and cylinder head LH.

      Tip:

      Tape the screwdriver tip before use.

  26. Click here

    REMOVE OIL CONTROL VALVE FILTER LH


    1. B00657HC01
      *1 Oil Control Valve Filter LH
      *2 Gasket
      *3 Cylinder Head Cover Spacer LH

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

    2. Remove the oil control valve filter LH from the cylinder head cover spacer LH.

  27. Click here

    REMOVE OIL CONTROL VALVE FILTER RH


    1. B00686VC01
      *1 Oil Control Valve Filter RH
      *2 Gasket
      *3 Cylinder Head Cover Spacer RH

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

    2. Remove the oil control valve filter RH from the cylinder head cover spacer RH.

  28. Click here

    REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. B006562C01
      *a 6 mm Hexagon Bolt

      Remove the bolt, 6 mm hexagon bolt and V-ribbed belt tensioner assembly.

  29. Click here

    REMOVE ENGINE WATER PUMP ASSEMBLY


    1. B0067WO

      Remove the 5 bolts, engine water pump assembly and water pump gasket from the timing chain cover assembly.

  30. Click here

    REMOVE TIMING CHAIN COVER ASSEMBLY

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  31. Click here

    REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL

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  32. Click here

    REMOVE INLET WATER PIPE


    1. B0066K4

      Remove the inlet water pipe.

    2. Remove the 2 O-rings from the inlet water pipe.

  33. Click here

    REMOVE NO. 1 OIL PIPE

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  34. Click here

    REMOVE NO. 2 OIL PIPE

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  35. Click here

    REMOVE NO. 3 OIL PIPE

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  36. Click here

    REMOVE SCAVENGING PUMP ASSEMBLY

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  37. Click here

    SET NO. 1 CYLINDER TO TDC / COMPRESSION


    1. Temporarily tighten the crankshaft pulley set bolt.

    2. B0066N2C01
      *a Timing Mark *b Timing Mark Position
      *c Knock Pin Position *d Approximately 2°
      *e Approximately 45° *f Approximately 16°
      *g Upward *h Timing Mark Position
      *i Approximately 20° *j Approximately 33°
      *k Key - -

      Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear assembly and camshaft timing gears are as shown in the illustration.

      Tip:

      If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

  38. Click here

    REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1)


    1. B0066XWC01
      *a Stopper Plate
      *b Plunger
      *c Pin

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

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

    3. B0065PL

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

    4. Remove the chain tensioner gasket.

  39. Click here

    REMOVE CHAIN TENSIONER SLIPPER (for Bank 1)


    1. B00673A

      Remove the chain tensioner slipper.

  40. Click here

    REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 1)


    1. B00650X

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

  41. Click here

    REMOVE CHAIN SUB-ASSEMBLY (for Bank 1)


    1. B0066O3C01
      *a Pin
      *b Plunger
      *c 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 secure it in place.

    2. B00669YC01
      *a Hold
      *b Turn

      Using a wrench, hold the hexagonal portion of the camshaft and loosen the bolt with a 12 mm hexagon socket wrench.

      Note:

      • Be careful not to damage the cylinder head with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

    3. B0067CKC01
      *a Hold
      *b Turn

      Using a wrench, hold the hexagonal portion of the camshaft and loosen the bolt with a wrench.

      Note:

      Be careful not to damage the cylinder head with the wrench.

    4. Remove the 2 bolts. Then with the chain sub-assembly and No. 2 chain sub-assembly still attached to the gears, remove the camshaft timing gear assembly, camshaft timing exhaust gear and crankshaft timing sprocket LH.

    5. Remove the chain sub-assembly and No. 2 chain sub-assembly from the gears.

  42. Click here

    REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B00668M

      Remove the 2 bolts and No. 3 chain tensioner assembly.

  43. Click here

    REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2)


    1. B0067F9C01
      *a Plunger
      *b Stopper Plate
      *c Pin

      Turn the stopper plate clockwise to release the lock, and fully push the plunger into the tensioner.

    2. Turn the stopper plate counterclockwise to set the lock, and insert a pin of 1.0 mm (0.0394 in.) diameter into the stopper plate hole.

    3. B0066ZA

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

  44. Click here

    REMOVE CHAIN TENSIONER SLIPPER (for Bank 2)


    1. B00670P

      Remove the chain tensioner slipper.

  45. Click here

    REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 2)


    1. B0067DI

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

  46. Click here

    REMOVE CHAIN SUB-ASSEMBLY (for Bank 2)


    1. B00666BC01
      *a Push
      *b Plunger
      *c Pin

      While pushing up the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to secure it in place.

    2. B006565C01
      *a Hold
      *b Turn

      Using a wrench, hold the hexagonal portion of the camshaft and loosen the bolt with a 12 mm hexagon socket wrench.

      Note:

      • Be careful not to damage the cylinder head with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

    3. B0066BPC01
      *a Hold
      *b Turn

      Using a wrench, hold the hexagonal portion of the camshaft and loosen the bolt with a wrench.

      Note:

      Be careful not to damage the cylinder head with the wrench.

    4. Remove the 2 bolts. Then with the chain sub-assembly and No. 2 chain sub-assembly still attached to the gears, remove the camshaft timing gear assembly, camshaft timing exhaust gear and crankshaft timing gear.

    5. Remove the chain sub-assembly and No. 2 chain sub-assembly from the gears.

  47. Click here

    REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B00677V

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

  48. Click here

    REMOVE CRANKSHAFT TIMING GEAR KEY


    1. B0066GY

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

  49. Click here

    REMOVE OIL REFLECTOR PLATE LH


    1. B0066OQ

      Remove the 2 bolts and oil reflector plate LH from the cylinder head LH.

  50. Click here

    REMOVE CAMSHAFT BEARING CAP (for Bank 1)

    Click here

  51. Click here

    REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

    Click here

  52. Click here

    REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

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  53. Click here

    REMOVE OIL REFLECTOR PLATE RH


    1. B00654A

      Remove the 2 bolts and oil reflector plate RH from the cylinder head sub-assembly.

  54. Click here

    REMOVE CAMSHAFT BEARING CAP (for Bank 2)

    Click here

  55. Click here

    REMOVE CAMSHAFT

    Click here

  56. Click here

    REMOVE NO. 2 CAMSHAFT

    Click here

  57. Click here

    REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. B0066LSC01
      *1 Valve Adjusting Shim
      *2 Cylinder Head Valve Rocker Arm Pivot

      Remove the 32 No. 1 valve rocker arm sub-assemblies from the cylinder head LH and cylinder head sub-assembly.

      Tip:

      Arrange the removed parts in such a way that they can be installed to their original locations.

  58. Click here

    REMOVE CYLINDER HEAD VALVE ROCKER ARM PIVOT LH


    1. Remove the 16 cylinder head valve rocker arm pivots LH from the cylinder head LH.

  59. Click here

    REMOVE CYLINDER HEAD VALVE ROCKER ARM PIVOT RH


    1. Remove the 16 cylinder head valve rocker arm pivots RH from the cylinder head sub-assembly.

  60. Click here

    REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  61. Click here

    REMOVE CYLINDER HEAD GASKET

    Click here

  62. Click here

    REMOVE CYLINDER HEAD LH

    Click here

  63. Click here

    REMOVE NO. 2 CYLINDER HEAD GASKET

    Click here

  64. Click here

    REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. B0067DW

      Remove the 2 cylinder block water jacket spacers from the cylinder block sub-assembly.

      Note:

      Be sure to remove the cylinder block water jacket spacers. Otherwise, they may fall out and be damaged when the cylinder block is inverted.

  65. Click here

    REMOVE HEAT EXCHANGER ASSEMBLY


    1. B0066WD

      Remove the bolt.

    2. B0066OV

      Remove the 11 bolts and 2 nuts.

    3. B0067E0

      Remove the heat exchanger assembly by prying between the heat exchanger assembly and cylinder block sub-assembly with a screwdriver.

      Tip:

      Tape the screwdriver tip before use.

  66. Click here

    REMOVE VENTILATION PIPE GASKET


    1. B00653G

      Using a screwdriver, pry out the ventilation pipe gasket.

      Tip:

      Tape the screwdriver tip before use.

  67. Click here

    REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. B00673DC01
      *a Nut

      Remove the 15 bolts and 2 nuts.

    2. B006845C04
      *1 Oil Pan Seal Cutter

      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 pan sub-assembly and No. 2 oil pan sub-assembly.

  68. Click here

    REMOVE OIL PAN SUB-ASSEMBLY


    1. B0065I7C01
      *a Nut

      Remove the 14 bolts and 2 nuts.

      Tip:

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

    2. B0066FNC02
      *A for Bank 1 Side
      *B for Bank 2 Side

      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.

      Tip:

      Tape the screwdriver tip before use.

  69. Click here

    REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. B0065LO

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

  70. Click here

    REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B00673W

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

  71. Click here

    REMOVE ENGINE REAR OIL SEAL RETAINER


    1. B0067U2

      Remove the 6 bolts.

    2. B0066U3C09
      *a Protective Tape

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

      Note:

      Be careful not to damage the engine rear oil seal retainer and cylinder block sub-assembly.

      Tip:

      Tape the screwdriver tip before use.

  72. Click here

    REMOVE ENGINE REAR OIL SEAL


    1. B0067LQC04
      *a Wooden Block

      Place the engine rear oil seal retainer on wooden blocks.

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

    3. B0065ELN06

      Using SST, tap in a new engine rear oil seal until its surface is flush with the engine rear oil seal retainer edge.

      09223-15030 09950-70010
      Note:

      • Keep the lip free from foreign matter.

      • Do not tap in the engine rear oil seal at an angle.

  73. Click here

    REMOVE OIL DRAIN PIPE SUB-ASSEMBLY


    1. B00673F

      Remove the bolt and oil drain pipe sub-assembly.

    2. Remove the O-ring from the oil drain pipe sub-assembly.