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ENGINE UNIT DISASSEMBLY

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  1. Click here

    REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY


    1. A0158EO

      Disconnect the sender gauge connector.

    2. A015AHE

      Remove the oil pressure sender gauge.

  2. Click here

    REMOVE OIL FILTER ELEMENT


    1. A015A6BE10

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

      Table 1. Text in Illustration
      *1 Pipe
      *2 Hose
    2. A01565V

      Remove the oil filter drain plug.

    3. A01567FE01

      Install the pipe to the oil filter cap.

      Table 2. Text in Illustration
      *1 Cap
      *2 Valve
      *3 Pipe
      *4 O-Ring
      *5 Hose
      Note:

      If the O-ring is removed with the drain plug, install the O-ring together with the pipe.

      Tip:

      Use a container to catch the draining oil.

    4. A0158W3

      Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring as shown in the illustration.

    5. A0155MKE02

      Using SST, remove the oil filter cap.

      09228-06501
      Table 3. Text in Illustration
      *1 Oil Filter Bracket Clip
      Note:

      Do not remove the oil filter bracket clip.

    6. A015DDVE02

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

      Table 4. Text in Illustration
      *1 Oil Filter Element
      *2 O-Ring
      Note:

      Be sure to remove the cap O-ring by hand, without using any tools, to prevent damage to the cap O-ring groove.

  3. Click here

    REMOVE NO. 1 OIL COOLER BRACKET


    1. A0156D4

      Remove the 2 nuts and bracket.

    2. Disconnect the ground wire from the cylinder block.

  4. Click here

    REMOVE OIL FILTER BRACKET


    1. A015AXQ

      Remove the 2 bolts, 2 nuts and filter bracket.

    2. A0156ZM

      Remove the 2 O-rings.

  5. Click here

    REMOVE OIL FILLER CAP SUB-ASSEMBLY

  6. Click here

    REMOVE OIL FILLER CAP HOUSING


    1. A015814

      Remove the 2 bolts, filler cap housing and gasket.

  7. Click here

    REMOVE SPARK PLUG


    1. Using a 16 mm plug wrench, remove the 8 spark plugs.

  8. Click here

    REMOVE VVT SENSOR


    1. A015CAU

      LH:

      Remove the 2 bolts and 2 VVT sensors.

    2. A015A7S

      RH:

      Remove the 2 bolts and 2 VVT sensors.

  9. Click here

    REMOVE CAMSHAFT POSITION SENSOR


    1. A0157RP

      Remove the bolt and camshaft position sensor.

  10. Click here

    REMOVE CRANK POSITION SENSOR PROTECTOR


    1. Remove the 2 bolts and sensor protector.

  11. Click here

    REMOVE CRANKSHAFT POSITION SENSOR


    1. A0157VO

      Remove the bolt and crankshaft position sensor.

  12. Click here

    REMOVE ENGINE OIL LEVEL SENSOR


    1. Disconnect the oil level sensor connector.

    2. A015A0I

      Remove the 4 bolts and oil level sensor.

    3. A0159LQE01
      Table 5. Text in Illustration
      *1 Cutting Position
      *2 Supply Part

      Cut off the gasket as shown in the illustration.

    4. Remove the gasket from the oil level sensor.

      Tip:

      After cutting away the parts of the gasket shown in the illustration, remove only the outer part of the gasket.

  13. Click here

    REMOVE CAMSHAFT OIL CONTROL VALVE ASSEMBLY


    1. A0155O4

      LH:

      Remove the 2 bolts and 2 oil control valves.

    2. A015CQU

      RH:

      Remove the 2 bolts and 2 oil control valves.

  14. Click here

    REMOVE WATER PUMP PULLEY


    1. A015BB7E03

      Using SST, hold the water pump pulley.

      09960-10010 09962-01000 09963-01000

    2. Remove the 4 bolts and water pump pulley.

  15. Click here

    REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A0155P5

      Remove the bolt and idler pulley.

  16. Click here

    REMOVE FLUID COUPLING BRACKET


    1. A015BB4

      Remove the 4 bolts and fluid coupling bracket.

  17. Click here

    REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01560I

      Remove the standard bolt, 6 mm hexagon wrench bolt and belt tensioner.

  18. Click here

    REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A0155S9

      Remove the 14 bolts, seal washer, cylinder head cover and gasket.

      Tip:

      Make sure the removed parts are returned to the same places they were removed from.

    2. A0157F1

      Remove the 5 gaskets from the camshaft bearing caps (No. 2, No. 3).

  19. Click here

    REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A0158AB

      Remove the bolt and noise filter.

    2. A015BOE

      Remove the 14 bolts, seal washer, cylinder head cover and gasket.

      Tip:

      Make sure the removed parts are returned to the same places they were removed from.

    3. A0157OB

      Remove the 5 gaskets from the camshaft bearing caps (No. 1, No. 3).

  20. Click here

    REMOVE OIL CONTROL VALVE FILTER


    1. A015D8ME03

      LH:

      Remove the 3 bolts, cylinder head cover spacer, gasket and filter.

      Table 6. Text in Illustration
      *1 Cylinder Head Cover Spacer
      *2 Gasket
      *3 Filter
    2. A0158UTE03

      RH:

      Remove the 3 bolts, cylinder head cover spacer, gasket and filter.

      Table 7. Text in Illustration
      *1 Cylinder Head Cover Spacer
      *2 Gasket
      *3 Filter
  21. Click here

    REMOVE SPARK PLUG TUBE GASKET


    1. Bend the 4 ventilation baffle plate claws on the cylinder head cover to an angle of 90° or more.

    2. Using a screwdriver, pry out the gaskets.

      Table 8. Text in Illustration
      *1 Tape
      A015DIT Pry
      Note:

      • Be careful not to damage the cylinder head cover.

      • Be careful not to damage the gasket when removing it, as the removed gasket needs to be used when installing a new one.

      Tip:

      Tape the screwdriver tip before use.

  22. Click here

    REMOVE CRANKSHAFT PULLEY


    1. A0157O6E04

      Using SST, loosen the crankshaft pulley set bolt until 2 or 3 threads are engaged.

      09213-70011
      09330-00021
      Table 9. Text in Illustration
      *a Hold
      A015DIT Turn
    2. A0156JUE03

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

      09950-50013 09951-05010 09952-05010 09953-05010 09954-05011
      Table 10. Text in Illustration
      *a Hold
      A015DIT Turn
  23. Click here

    REMOVE WATER PUMP ASSEMBLY


    1. A015E4W

      Remove the 8 bolts, water pump and gasket.

  24. Click here

    REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01595X

      Remove the 28 bolts and nut shown in the illustration.

      Table 11. Text in Illustration
      A015DIT Bolt
      A015CC1 Nut
    2. A015B5A

      Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver as shown in the illustration.

      Note:

      Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.

      Tip:

      Tape the screwdriver tip before use.

    3. A0157TF

      Remove the oil pump gasket from the cylinder block.

    4. A0155SQ

      Remove the O-ring from the oil pan.

  25. Click here

    REMOVE WATER INLET PIPE


    1. A0158TJ

      Remove the water inlet pipe.

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

  26. Click here

    REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A0156VXE02

      Place the timing chain cover on wooden blocks.

    2. Using a screwdriver and wooden block, pry out the oil seal.

      Table 12. Text in Illustration
      *1 Wooden Block
      Note:

      Do not damage the surface of the oil seal press fit hole.

      Tip:

      Tape the screwdriver tip before use.

  27. Click here

    SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

    2. A0156GJE02

      Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing sprocket 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.

      Table 13. Text in Illustration
      *1 Timing Mark *2 Timing Mark Position
      *3 Knock Pin Position *4 Key
      *a Toward Ceiling *b Approximately 2°
      *c Approximately 45° *d Approximately 16°
      *e Approximately 18° *f Approximately 32°
  28. Click here

    REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH


    1. A015A46E02

      Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

      Table 14. Text in Illustration
      *1 Plunger
      *2 Stopper Plate
    2. A015DSXE02

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

      Table 15. Text in Illustration
      *1 Plunger
      *2 Stopper Plate
    3. A015755

      Remove the 2 bolts, chain tensioner and gasket.

  29. Click here

    REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

  30. Click here

    REMOVE NO. 1 CHAIN VIBRATION DAMPER LH


    1. Remove the 2 bolts and chain vibration damper.

  31. Click here

    REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH


    1. A0158J7E02

      While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

      Table 16. Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push
    2. A015A4RE02

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

      Table 17. Text in Illustration
      *a Hold
      A015DIT Turn
      Note:

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

      • Do not disassemble the camshaft timing gear.

    3. A0156ZJE02

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

      Table 18. Text in Illustration
      *a Hold
      A015DIT Turn
      Note:

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

    4. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket LH.

    5. Remove the No. 1 and No. 2 chains from the gears.

  32. Click here

    REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. Remove the 2 bolts and chain tensioner.

  33. Click here

    REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH


    1. A015B2PE02

      Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

      Table 19. Text in Illustration
      *1 Plunger
      *2 Stopper Plate
    2. A0157NFE02

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

      Table 20. Text in Illustration
      *1 Plunger
      *2 Stopper Plate
    3. A015C5P

      Remove the 2 bolts and chain tensioner.

  34. Click here

    REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

  35. Click here

    REMOVE NO. 1 CHAIN VIBRATION DAMPER RH


    1. Remove the 2 bolts and vibration damper.

  36. Click here

    REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH


    1. A015E4RE02

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

      Table 21. Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push
    2. A015B0CE02

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

      Table 22. Text in Illustration
      *a Hold
      A015DIT Turn
      Note:

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

      • Do not disassemble the camshaft timing gear.

    3. A0156CXE02

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

      Table 23. Text in Illustration
      *a Hold
      A015DIT Turn
      Note:

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

    4. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket RH.

    5. Remove the No. 1 and No. 2 chains from the gears.

  37. Click here

    REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. Remove the 2 bolts and chain tensioner.

  38. Click here

    REMOVE CRANKSHAFT TIMING GEAR KEY


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

  39. Click here

    REMOVE CAMSHAFT BEARING CAP LH


    1. A015BEDE03

      Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

      Table 24. Text in Illustration
      *1 IN
      *2 EX
      *3 Knock Pin
    2. A015BV1E03

      Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

    3. A0158AOE03

      Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

      Note:

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 6 bearing caps.

      Tip:

      Arrange the removed parts in the correct order.

    5. Remove the No. 3 and No. 4 camshafts.

  40. Click here

    REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A0157MK

      Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

      Note:

      Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

      Tip:

      Tape the screwdriver tip before use.

  41. Click here

    REMOVE CAMSHAFT BEARING CAP RH


    1. A0157ZFE03

      Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

      Table 25. Text in Illustration
      *1 EX
      *2 IN
      *3 Knock Pin
    2. A015CH9E03

      Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

    3. A015AT2E03

      Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

      Note:

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 6 bearing caps.

      Tip:

      Arrange the removed parts in the correct order.

    5. Remove the No. 1 and No. 2 camshafts.

  42. Click here

    REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A015CD7

      Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

      Note:

      Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

      Tip:

      Tape the screwdriver tip before use.

  43. Click here

    REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. Remove the 32 valve rocker arms from the cylinder heads.

      Tip:

      Arrange the removed parts in the correct order.

  44. Click here

    REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 32 valve lash adjusters from the cylinder heads.

      Tip:

      Arrange the removed parts in the correct order.

  45. Click here

    REMOVE VALVE STEM CAP


    1. Remove the 32 valve stem caps from the cylinder heads.

      Tip:

      Arrange the removed parts in the correct order.

  46. Click here

    REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. A01554AE05

      Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

    2. A0159FJE05

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

      Note:

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

      • Head warpage or cracking could result from removing bolts in an incorrect order.

      Tip:

      Be sure to arrange the removed parts for each installation position separately.

    3. Remove the cylinder head and gasket.

  47. Click here

    REMOVE CYLINDER HEAD SUB-ASSEMBLY RH


    1. A01571FE04

      Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

    2. A0158VTE03

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

      Note:

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

      • Head warpage or cracking could result from removing bolts in an incorrect order.

      Tip:

      Be sure to arrange the removed parts for each installation position separately.

    3. Remove the cylinder head and gasket.

  48. Click here

    REMOVE CYLINDER BLOCK WATER JACKET SPACER


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

      Note:

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

  49. Click here

    REMOVE VENTILATION PIPE GASKET


    1. A0158L6

      Using a screwdriver, pry out the ventilation pipe gasket.

      Tip:

      Tape the screwdriver tip before use.

  50. Click here

    REMOVE NO. 1 HEAT EXCHANGER COVER


    1. A0159ZS

      Remove the 12 bolts and 2 nuts.

      Table 26. Text in Illustration
      A015DIT Bolt
      A015CC1 Nut
    2. A0159PN

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

      Tip:

      Tape the screwdriver tip before use.

  51. Click here

    REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A0156QF

      Remove the 14 bolts and 2 nuts.

      Table 27. Text in Illustration
      A015DIT Bolt
      A015CC1 Nut
    2. A015BAU

      Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

      Note:

      Be careful not to damage the contact surfaces of the oil pans.

  52. Click here

    REMOVE NO. 1 OIL PAN SUB-ASSEMBLY


    1. A01566B

      Remove the 14 bolts and 2 nuts.

      Table 28. Text in Illustration
      A015DIT Bolt
      A015CC1 Nut
      Tip:

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

    2. A0158V1E03

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

      Table 29. Text in Illustration
      *A LH Side
      *B RH Side
      Note:

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

      Tip:

      Tape the screwdriver tip before use.

  53. Click here

    REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A015737

      Remove the 7 bolts and baffle plate.

  54. Click here

    REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A015AEI

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

  55. Click here

    REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A015CJC

      Remove the 6 bolts and oil seal retainer.

    2. A015BCZ

      Using a screwdriver, pry out the oil seal retainer.

      Tip:

      Tape the screwdriver tip before use.

  56. Click here

    REMOVE OIL DRAIN PIPE SUB-ASSEMBLY


    1. A0157E2

      Remove the bolt and oil drain pipe.

    2. Remove the O-ring.

  57. Click here

    REMOVE REAR CRANKSHAFT OIL SEAL


    1. A0159KKE02

      Place the oil seal retainer on wooden blocks.

      Table 30. Text in Illustration
      *1 Wooden Block

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

  58. Click here

    REMOVE RING PIN

    Note:

    It is not necessary to remove the ring pin unless it is being replaced.

  59. Click here

    REMOVE STUD BOLT

    Note:

    If the stud bolt is deformed or its threads are damaged, replace it.