ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


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

  2. REMOVE SPARK PLUG


    1. A01G7YQ

      Remove the 6 spark plugs.

  3. REMOVE OIL PAN DRAIN PLUG


    1. A01G516

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

  4. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A01G7NW

      Remove the ventilation valve sub-assembly.

  5. REMOVE VVT SENSOR


    1. Disconnect the 4 VVT sensor connectors.

    2. A01G6QDE02
      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 VVT sensors.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. Disconnect the 4 camshaft timing oil control valve assembly connectors.

    2. A01G50CE01
      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 camshaft timing oil control valve assemblies.

    3. A01G8MOE06
      Text in Illustration
      *1 O-ring

      Remove the O-ring from each camshaft oil control valve assembly.

  7. REMOVE CRANK POSITION SENSOR


    1. A01G4N8

      Disconnect the crank position sensor connector.

    2. Remove the bolt and crank position sensor.

  8. REMOVE NO. 1 OIL PIPE


    1. A01G5QEE02
      Text in Illustration
      *1 Oil Pipe Union

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

    2. Remove the oil control valve filter LH.

  9. REMOVE OIL PIPE


    1. A01G79BE04
      Text in Illustration
      *1 Oil Pipe Union
      *2 Bolt

      Remove the bolt.

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

    3. Remove the oil control valve filter RH.

  10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

    A01G87KE07
    Text in Illustration
    *a for Bank 1
    *b for Bank 2

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

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

  11. REMOVE OIL FILTER CAP ASSEMBLY


    1. A01G7X6E01
      Text in Illustration
      *1 Pipe
      *2 Hose

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

    2. A01G57W

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

    3. A01G944E02
      Text in Illustration
      *1 Oil Filter Cap Assembly
      *2 O-ring
      *3 Pipe

      Insert the pipe with the hose into the oil filter cap assembly.

      Note

      Be sure to insert the pipe with the O-ring installed on the oil filter cap assembly.

      Tech Tips

      Place the hose end into a container before draining oil from the hose.

    4. A01G69J

      Make sure that the 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. A01G6B5E01

      Using SST, remove the oil filter cap assembly.

      SST
      09228-06501
    6. A01G5AQE06
      Text in Illustration
      *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.

  12. REMOVE CRANKSHAFT PULLEY


    1. A01G4TGE03
      Text in Illustration
      *a Hold
      A01G8AH Turn

      Using SST, loosen the crankshaft pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A01G4MTE01
      Text in Illustration
      *a Hold
      A01G8AH Turn

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
    3. A01G7K3

      Remove the pulley set key from the crankshaft.

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


    1. A01G6U6

      Remove the bolt, 2 clamps, 4 clips, No. 4 water by-pass hose and No. 5 water by-pass hose.

    2. A01G8LK

      Remove the oil cooler union bolt, oil cooler assembly and O-ring.

  14. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)


    1. A01G7GA

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

    2. A01G7YUE01
      Text in Illustration
      *1 Nut
      *2 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.

  15. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01G90F

      Remove the engine oil level dipstick guide.

    2. A01G587

      Remove the O-ring.

  16. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A01G6AR

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

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

  17. REMOVE WATER INLET HOUSING


    1. A01G540

      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. A01G9QHE04
      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. A01G4OH

      Remove the 2 O-rings.

  18. REMOVE WATER OUTLET


    1. A01G6G6E01
      Text in Illustration
      *A w/ Oil Cooler
      *B w/o Oil Cooler
      *1 Nut
      *2 Bolt

      Remove the 2 bolts, 4 nuts and water outlet.

    2. A01G5DK

      Remove the 2 gaskets and O-ring.

  19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01G5LGE03
      Text in Illustration
      *1 Seal Washer

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

    2. A01G6GM

      Remove the 3 gaskets.

  20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01G5VNE07
      Text in Illustration
      *1 Baffle Plate
      *2 Seal Washer

      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. A01G4HP

      Remove the 3 gaskets.

  21. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01G5WAE02
      Text in Illustration
      *1 Nut

      Remove the 16 bolts and 2 nuts.

    2. A01G7TQ

      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.

  22. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01G751E03
      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.

  23. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01G7EWE01
      Text in Illustration
      *1 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. A01G6D5E02
      Text in Illustration
      *1 Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

    3. A01G76L

      Remove the 2 O-rings.

    4. w/ Oil Cooler


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

    5. w/o Oil Cooler


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

  24. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01G73G

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

  25. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01G84D

      Remove the 6 bolts.

    2. A01G7TAE02
      Text in Illustration
      *1 Protective Tape
      A01G8AH 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.

  26. REMOVE ENGINE REAR OIL SEAL


    1. A01G62VE07
      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.

  27. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01G7GJ

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

  28. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01G9N9E02
      Text in Illustration
      *1 Nut

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

    2. A01G4H0E04
      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 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. A01G497

      Remove the gasket.

  29. REMOVE TIMING CHAIN CASE OIL SEAL


    1. A01G4PPE05
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

      Using a screwdriver and wooden block, pry out the timing chain case oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  30. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily tighten the pulley set bolt.

    2. A01G8YAE02
      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. A01G49KE07
      Text in Illustration
      *a Timing Mark

      Check that the timing marks of the camshaft timing gear assemblies are aligned with the timing marks of the bearing cap as shown in the illustration.

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

  31. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01G9OYE06
      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 tensioner.

    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. A01G5OG

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

  32. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  33. REMOVE CHAIN SUB-ASSEMBLY


    1. A01G8I7E02
      Text in Illustration
      *1 Sensor Plate
      *a Center Line
      *b Timing Mark

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

    2. Remove the pulley set bolt.

    3. A01G77C

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

    4. A01G450E13
      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.

  34. REMOVE IDLE SPROCKET ASSEMBLY


    1. A01G4V4

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

  35. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01G5XW

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

  36. REMOVE NO. 2 CHAIN VIBRATION DAMPER


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

  37. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01G492

      Remove the crankshaft timing sprocket from the crankshaft.

    2. Remove the 2 keys from the crankshaft.

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


    1. A01G6T5E08
      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. A01G4KJE06
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, loosen the 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 sub-assembly RH 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 assemblies together with the No. 2 chain sub-assembly.

  39. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01G4B5

      Remove the bolt and No. 2 chain tensioner assembly.

  40. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A01G7XZE08
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A01G57SE03

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

    3. A01G5XZE01

      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.

  41. REMOVE CAMSHAFT


    1. Remove the camshaft.

  42. REMOVE NO. 2 CAMSHAFT


    1. Remove the No. 2 camshaft.

  43. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01G79ME02
      Text in Illustration
      *1 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.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. A01G58BE07
      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. A01G5BWE06
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, loosen the 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 sub-assembly LH 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 assemblies together with the No. 2 chain sub-assembly.

  45. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01G4SO

      Remove the bolt and No. 3 chain tensioner assembly.

  46. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A01G50IE06
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A01G9RTE03

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

    3. A01G8JTE01

      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.

  47. REMOVE NO. 3 CAMSHAFT


    1. Remove the No. 3 camshaft.

  48. REMOVE NO. 4 CAMSHAFT


    1. Remove the No. 4 camshaft.

  49. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01G4XLE02
      Text in Illustration
      *1 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.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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


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

      Tech Tips

      Arrange the removed parts in the correct order.

  51. 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 the correct order.

  52. REMOVE VALVE STEM CAP


    1. Remove the 24 valve stem caps.

  53. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH


    1. A01G45IE01

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

      Note


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

      • Cylinder head sub-assembly RH 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.

  54. REMOVE CYLINDER HEAD GASKET RH


    1. Remove the cylinder head gasket RH.

  55. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. A01G6L7E01

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

    2. A01G9FBE01

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

      Note


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

      • Cylinder head sub-assembly LH 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.

  56. REMOVE CYLINDER HEAD GASKET LH


    1. Remove the cylinder head gasket LH.

  57. REMOVE WATER INLET PIPE


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

    2. A01G5B7

      Remove the 2 bolts and water inlet pipe.