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

    Click here

  3. REMOVE OIL PAN DRAIN PLUG


    1. B006LZ5

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

  4. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

  13. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  14. REMOVE NO. 1 OIL PIPE


    1. B006QS8C01
      *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. B006R49C07
      *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 procedure only when a taper screw plug is installed.


    1. B006MOY

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

  17. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

    B006N32C01
    *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 procedure 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

    Click here

  19. REMOVE CRANKSHAFT PULLEY

    Click here

  20. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. B006PJW

      Remove the bolt and engine oil level dipstick guide.

    2. B006Q7L

      Remove the O-ring.

  21. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. B006M2L

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

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

  22. REMOVE WATER OUTLET


    1. B006RJNC02
      *a Nut
      *b Bolt

      Remove the 2 bolts, 4 nuts and water outlet.

    2. B006RJE

      Remove the 2 water outlet gaskets and O-ring.

  23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B006OCXC06
      *1 Bolt with Cylinder Head Cover Seal Washer

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

    2. B006MUL

      Remove the 3 gaskets.

  24. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. B006NX5C01
      *1 Bolt with Cylinder Head Cover Seal Washer
      *a Baffle Plate

      Remove the 12 bolts, cylinder head cover seal washer, cylinder head cover sub-assembly LH and No. 2 cylinder head cover gasket.

      Note

      The baffle plate is located on the underside of the area shown in the illustration. Do not damage the baffle plate when removing the cylinder head cover sub-assembly LH.

    2. B006RKX

      Remove the 3 gaskets.

  25. REMOVE SPARK PLUG TUBE GASKET


    1. B006NC2

      Pry up the claws of the ventilation baffle plate.

      Note

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

    2. B006LQT

      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 sub-assembly.

      Note


      • As much as possible prevent the spark plug tube gaskets from being deformed.

        The removed spark plug tube gaskets will be used when reinstalling the new spark plug tube gaskets.

      • Do not damage the cylinder head cover sub-assembly.

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

      Tech Tips

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

  26. REMOVE WATER INLET

    Click here

  27. REMOVE THERMOSTAT

    Click here

  28. REMOVE DRAIN COCK ASSEMBLY


    1. B006KV1

      Remove the drain cock assembly from the water inlet housing.

  29. REMOVE WATER INLET HOUSING


    1. Remove the 2 stud bolts.

    2. Remove the water inlet housing.

      Click here

  30. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. B006QHFC06
      *a Nut

      Remove the 16 bolts and 2 nuts.

    2. B006MMH

      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.

  31. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B006OCTC07
      *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.

  32. REMOVE OIL PAN SUB-ASSEMBLY


    1. Remove the oil pan sub-assembly.

      Click here

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

      B006NKNC03
      *A Type A *B Type B
      *a Timing Chain Cover Sub-assembly Side *b Cylinder Block Sub-assembly Bottom Side

  33. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. B006LYV

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

  34. REMOVE REAR ENGINE OIL SEAL RETAINER


    1. B006N5U

      Remove the 6 bolts.

    2. B006PMLC06
      *a Protective Tape
      B006QOD Pry

      Using a screwdriver with its tip wrapped with protective tape, pry out the rear engine oil seal retainer.

      Note

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

  35. REMOVE REAR ENGINE OIL SEAL


    1. B006P7KC04
      *a Protective Tape
      *b Wooden Block

      Place the rear engine oil seal retainer on wooden blocks.

    2. Using a hammer and a screwdriver with its tip wrapped with protective tape, tap out the rear engine oil seal.

      Note

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

  36. REMOVE ENGINE WATER PUMP ASSEMBLY

    Click here

  37. REMOVE TIMING CHAIN COVER PLATE


    1. B006QNV

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

  38. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  39. REMOVE TIMING CHAIN CASE OIL SEAL

    Click here

  40. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  41. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B006RH3C12
      *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. B006O6L

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

  42. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  43. REMOVE CHAIN SUB-ASSEMBLY


    1. B006M0NC05
      *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. B006L53

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

    4. B006N77C01
      *A for Bank 1

      Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) so that it is positioned as shown in the illustration.

      Note

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

    5. Remove the chain sub-assembly.

  44. REMOVE IDLE SPROCKET ASSEMBLY


    1. B006QZX

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

  45. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B006QYP

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

  46. REMOVE NO. 2 CHAIN VIBRATION DAMPER


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

  47. REMOVE CRANKSHAFT TIMING SPROCKET


    1. B006P4E

      Remove the crankshaft timing sprocket from the crankshaft.

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

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


    1. B006NZWC06
      *a Pin
      *b Plunger
      *c Push

      While raising the No. 2 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the hole to secure the No. 2 chain tensioner assembly.

    2. B006M5VC08
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, loosen the bolt 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 sub-assembly RH with SST.

      • Do not loosen any other bolt. If any other bolt 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, camshaft timing gear assembly and camshaft timing exhaust gear assembly together with the No. 2 chain sub-assembly.

  49. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B006LZY

      Remove the bolt and No. 2 chain tensioner assembly.

  50. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. B006O71C10
      *a Knock Pin
      *b Front View
      *c 45°

      Check that the camshaft and No. 2 camshaft are positioned as shown in the illustration.

    2. B006PITN09

      Uniformly loosen and remove the 8 bolts in several steps in the order shown in the illustration.

    3. B006R2GN06

      Uniformly loosen and remove the 12 bolts in several steps in the order shown in the illustration.

      Note

      Make sure that the camshaft and No. 2 camshaft remains level while uniformly loosening the bolts.

    4. Remove the 5 camshaft bearing caps.

  51. REMOVE CAMSHAFT

    Click here

  52. REMOVE NO. 2 CAMSHAFT

    Click here

  53. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. B006KVNC03
      *a Protective Tape

      Remove the camshaft housing sub-assembly RH by prying between the cylinder head sub-assembly RH and camshaft housing sub-assembly RH with a screwdriver with its tip wrapped with protective tape.

      Note

      Be careful not to damage the contact surfaces of the cylinder head sub-assembly RH and camshaft housing sub-assembly RH.

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


    1. B006RJ5C09
      *a Pin
      *b Plunger
      *c Push

      While pushing down the No. 3 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the hole to secure the No. 3 chain tensioner assembly.

    2. B006MXOC04
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, loosen the bolt 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 sub-assembly LH with SST.

      • Do not loosen any other bolt. If any other bolt 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, camshaft timing gear assembly and camshaft timing exhaust gear assembly together with the No. 2 chain sub-assembly.

  55. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B006M2C

      Remove the bolt and No. 3 chain tensioner assembly.

  56. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. B006QQ7C03
      *a Knock Pin
      *b Front View

      Check that the No. 3 camshaft and No. 4 camshaft are positioned as shown in the illustration.

    2. B006Q7UN10

      Uniformly loosen and remove the 8 bolts in several steps in the order shown in the illustration.

    3. B006Q9MN05

      Uniformly loosen and remove the 13 bolts in several steps in the order shown in the illustration.

      Note

      Make sure that the No. 3 camshaft and No. 4 camshaft remains level while uniformly loosening the bolts.

    4. Remove the 5 camshaft bearing caps.

  57. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

    Click here

  58. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

    Click here

  59. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. B006QA9C03
      *a Protective Tape

      Remove the camshaft housing sub-assembly LH by prying between the cylinder head sub-assembly LH and camshaft housing sub-assembly LH with a screwdriver with its tip wrapped with protective tape.

      Note

      Be careful not to damage the contact surfaces of the cylinder head sub-assembly LH and camshaft housing sub-assembly LH.

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


    1. Remove the 24 No. 1 valve rocker arm sub-assemblies.

      Tech Tips

      Arrange the removed parts in such away that they can be reinstalled to their original locations.

  61. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 24 valve lash adjuster assemblies from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in such away that they can be reinstalled to their original locations.

  62. REMOVE VALVE STEM CAP


    1. Remove the 24 valve stem caps.

      Tech Tips

      Arrange the removed parts in such away that they can be reinstalled to their original locations.

  63. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B006L0BN07

      Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 cylinder head set bolts in the order shown in the illustration. Remove the 8 cylinder head set bolts and plate washers.

      Note


      • Be careful not to drop plate washers into the cylinder head sub-assembly.

      • Warpage or cracking of the cylinder head sub-assembly may result from removing bolts in the incorrect order.

      Tech Tips

      Arrange the removed parts in such away that they can be reinstalled to their original locations.

    2. Remove the cylinder head sub-assembly.

  64. REMOVE CYLINDER HEAD GASKET

    Click here

  65. REMOVE CYLINDER HEAD LH


    1. B006OL0N10

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

    2. B006KYHN06

      Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 cylinder head set bolts in the order shown in the illustration. Remove the 8 cylinder head set bolts and plate washers.

      Note


      • Be careful not to drop plate washers into the cylinder head LH.

      • Warpage or cracking of the cylinder head LH may result from removing bolts in the incorrect order.

      Tech Tips

      Arrange the removed parts in such away that they can be reinstalled to their original locations.

    3. Remove the cylinder head LH.

  66. REMOVE NO. 2 CYLINDER HEAD GASKET

    Click here

  67. REMOVE WATER INLET PIPE


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

    2. B006MN0

      Remove the 2 bolts and water inlet pipe.