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ENGINE UNIT DISASSEMBLY

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  1. 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. A0159CHE01

      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.

  2. Click here

    REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY


    1. A0158EO

      Disconnect the oil pressure sender gauge connector.

    2. A015AHE

      Remove the oil pressure sender gauge.

  3. Click here

    REMOVE OIL FILTER BRACKET SUB-ASSEMBLY


    1. A015AXQ

      Remove the 2 bolts, 2 nuts and filter bracket.

    2. A0156ZM

      Remove the 2 O-rings.

  4. Click here

    REMOVE CRANKSHAFT PULLEY


    1. A0157O6E03

      Using SST, remove the crankshaft pulley set bolt.

      09213-70011
      09330-00021
      Table 5. Text in Illustration
      *a Hold
      A015DIT Turn

    2. Temporarily install the pulley set bolt to the crankshaft until 2 or 3 threads are engaged.

    3. A0156JUE02

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

      09950-50013 09951-05010 09952-05010 09953-05010 09954-05011
      Table 6. Text in Illustration
      *a Hold
      A015DIT Turn
  5. Click here

    REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap.

    2. Remove the gasket from the oil filler cap.

  6. Click here

    REMOVE OIL FILLER CAP HOUSING


    1. A01581D

      Remove the 2 bolts, oil 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 KNOCK SENSOR


    1. A0157AT

      Disconnect the 4 knock sensor connectors.

    2. Remove the 4 bolts and 4 knock sensors.

  9. Click here

    REMOVE VVT SENSOR


    1. A015CTLE05

      Disconnect the 4 VVT sensor connectors.

      Table 7. Text in Illustration
      *A for Bank 2
      *B for Bank 1

    2. Remove the 4 bolts and 4 VVT sensors.

  10. Click here

    REMOVE CAMSHAFT POSITION SENSOR


    1. A01581V

      Disconnect the camshaft position sensor connector.

    2. Remove the bolt and camshaft position sensor.

  11. Click here

    REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR


    1. A01555R

      Remove the 2 bolts and crankshaft position sensor protector.

  12. Click here

    REMOVE CRANKSHAFT POSITION SENSOR


    1. A015DRY

      Disconnect the crankshaft position sensor connector.

    2. Remove the bolt and crankshaft position sensor.

  13. Click here

    REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A015AGV

      for Bank 1:

      Remove the 2 bolts and 2 camshaft oil control valves.

    2. A0159ZU

      for Bank 2:

      Remove the 2 bolts and 2 camshaft oil control valves.

  14. Click here

    REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A0158R8E03

      Remove the 2 water drain cock plugs from the cylinder block water drain cocks.

      Table 8. Text in Illustration
      *A for LH Side
      *B for RH Side

    2. Remove the 2 cylinder block water drain cocks from the cylinder block.

  15. Click here

    REMOVE WATER INLET HOUSING


    1. A015DNS

      Remove the 3 bolts and water inlet housing.

    2. Remove the gasket from the engine water pump.

  16. Click here

    REMOVE FRONT WATER BY-PASS JOINT


    1. A0159HA

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

  17. Click here

    REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A0155B6

      Remove the 14 bolts, seal washer, cylinder head cover sub-assembly LH and cylinder head cover gasket LH.

      Tip:

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

    2. A015DUW

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

      Table 9. Text in Illustration
      A0155IU Gasket
  18. Click here

    REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A0159EN

      Remove the 14 bolts, seal washer, cylinder head cover sub-assembly RH and cylinder head cover gasket RH.

      Tip:

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

    2. A015A4J

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

      Table 10. Text in Illustration
      A0155IU Gasket
  19. Click here

    REMOVE OIL CONTROL VALVE FILTER


    1. A015D8ME02

      for Bank 1:

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

      Table 11. Text in Illustration
      *1 Cylinder Head Cover Spacer
      *2 Gasket
      *3 Oil Control Valve Filter
    2. A0158UTE02

      for Bank 2:

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

      Table 12. Text in Illustration
      *1 Cylinder Head Cover Spacer
      *2 Gasket
      *3 Oil Control Valve Filter
  20. Click here

    REMOVE SPARK PLUG TUBE GASKET


    1. A015DZRE01

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

      Table 13. Text in Illustration
      *1 Ventilation Baffle Plate Claw
      *2 Protective Tape

    2. Using a screwdriver, pry out the gaskets.

      Note:

      Be careful not to damage the cylinder head cover.

      Tip:

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

      • Tape the screwdriver tip before use.

  21. 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

      Cut away part of the gasket and remove the gasket from the engine oil level sensor.

      Table 14. Text in Illustration
      *1 Cutting Position
      *2 Supply Part
      Tip:

      Remove the only the outer part of the gasket.

  22. Click here

    REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01560I

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

  23. Click here

    REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A0159E6

      Remove the 26 bolts and nut shown in the illustration.

    2. A015964

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

      Table 15. Text in Illustration
      A0155U9 Protective Tape
      Note:

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

      Tip:

      Tape the screwdriver tip before use.

    3. A01577D

      Remove the gasket from the cylinder block.

    4. A0155SQ

      Remove the O-ring from the oil pan.

  24. Click here

    REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A015BPY

      Remove the 8 bolts, engine water pump and gasket.

  25. Click here

    REMOVE WATER INLET PIPE


    1. A0156P1

      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. Place the timing chain cover on wooden blocks.

    2. A01566EE02

      Place the oil pump on a wooden block.

      Table 16. Text in Illustration
      *1 Wooden Block
      *2 Protective Tape

    3. Using a screwdriver and wooden block, pry out the front crankshaft oil seal.

      Note:

      Do not damage the surface of the front crankshaft 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 pulley set bolt.

    2. A015CEKE02

      Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear 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 17. Text in Illustration
      *1 Crankshaft Timing Gear Key *2 Timing Mark
      *a Toward Ceiling *b Timing Mark Position
      *c Knock Pin Position *d Approximately 2°
      *e Approximately 45° *f Approximately 16°
      *g Approximately 18° *h Approximately 32°
  28. Click here

    REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH


    1. A0156KQE02

      Move the stopper plate upward to release the lock and push the plunger deep into the No. 1 chain tensioner.

      Table 18. Text in Illustration
      *1 Plunger
      *2 Stopper Plate
    2. A0158DVE02

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

      Table 19. Text in Illustration
      *1 Plunger
      *2 Stopper Plate
      *3 Hexagon Wrench
    3. A015A62

      Remove the 2 bolts, No. 1 chain tensioner LH and gasket.

  29. Click here

    REMOVE CHAIN TENSIONER SLIPPER LH

  30. Click here

    REMOVE NO. 1 CHAIN VIBRATION DAMPER LH


    1. A015CEY

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

  31. Click here

    REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH


    1. A0158WWE02

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

      Table 20. Text in Illustration
      *1 Pin
      *2 Plunger
      *3 No. 3 Chain Tensioner
      *a Push
    2. A015AM0E02

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

      Table 21. 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. A015E01E02

      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 exhaust gear.

    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. A015A53

      Remove the 2 bolts and No. 3 chain tensioner.

  33. Click here

    REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH


    1. A0157SBE02

      Move the stopper plate upward to release the lock and push the plunger deep into the No. 1 chain tensioner.

      Table 23. Text in Illustration
      *1 Plunger
      *2 Stopper Plate
    2. A0157W8E02

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

      Table 24. Text in Illustration
      *1 Plunger
      *2 Stopper Plate
      *3 Hexagon Wrench
    3. A015B10

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

  34. Click here

    REMOVE CHAIN TENSIONER SLIPPER RH

  35. Click here

    REMOVE NO. 1 CHAIN VIBRATION DAMPER RH


    1. A015B3O

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

  36. Click here

    REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH


    1. A01591IE02

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

      Table 25. Text in Illustration
      *1 Pin
      *2 Plunger
      *3 No. 2 Chain Tensioner
      *a Push
    2. A015BGDE02

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

      Table 26. 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. A0157OOE02

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

      Table 27. 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 exhaust gear.

    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. A01595D

      Remove the 2 bolts and No. 2 chain tensioner.

  38. Click here

    REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A015CLH

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

  39. Click here

    REMOVE CAMSHAFT BEARING CAP LH


    1. A015813E02

      Make sure that the knock pins of the camshafts are positioned as shown in the illustration.

      Table 28. Text in Illustration
      *A for Intake Side
      *B for Exhaust Side
      *1 Knock Pin
    2. A0158DOE01

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

    3. A0158XSE01

      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 camshaft bearing caps.

      Tip:

      Arrange the removed parts in the correct order.

  40. Click here

    REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY


    1. Remove the No. 3 camshaft from the camshaft housing LH.

  41. Click here

    REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY


    1. Remove the No. 4 camshaft from the camshaft housing LH.

  42. Click here

    REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A015604E01

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

      Table 29. Text in Illustration
      *1 Protective Tape
      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 CAMSHAFT BEARING CAP RH


    1. A01570NE02

      Make sure that the knock pins of the camshafts are positioned as shown in the illustration.

      Table 30. Text in Illustration
      *A for Exhaust Side
      *B for Intake Side
      *1 Knock Pin
    2. A015CH9E05

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

    3. A015AT2E04

      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 camshaft bearing caps.

      Tip:

      Arrange the removed parts in the correct order.

  44. Click here

    REMOVE NO. 1 CAMSHAFT SUB-ASSEMBLY


    1. Remove the No. 1 camshaft from the camshaft housing RH.

  45. Click here

    REMOVE NO. 2 CAMSHAFT SUB-ASSEMBLY


    1. Remove the No. 2 camshaft from the camshaft housing RH.

  46. Click here

    REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A015AK1E01

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

      Table 31. Text in Illustration
      *1 Protective Tape
      Note:

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

      Tip:

      Tape the screwdriver tip before use.

  47. Click here

    REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. Remove the 32 No. 1 valve rocker arms from the cylinder head.

      Tip:

      Arrange the removed parts in the correct order.

  48. Click here

    REMOVE VALVE LASH ADJUSTER ASSEMBLY


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

      Tip:

      Arrange the removed parts in the correct order.

  49. Click here

    REMOVE VALVE STEM CAP


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

      Tip:

      Arrange the removed parts in the correct order.

  50. Click here

    REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. A01554AE07

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

    2. A0159FJE07

      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 LH.

  51. Click here

    REMOVE NO. 2 CYLINDER HEAD GASKET

  52. Click here

    REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01571FE06

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

    2. A0158VTE05

      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.

  53. Click here

    REMOVE CYLINDER HEAD GASKET

  54. Click here

    REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A015C1T

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

      Note:

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

  55. Click here

    REMOVE OIL RETURN PIPE GASKET


    1. A015DF6E01

      Using a screwdriver, pry out the oil return pipe gasket.

      Table 32. Text in Illustration
      *1 Protective Tape
      Tip:

      Tape the screwdriver tip before use.

  56. Click here

    REMOVE VENTILATION PIPE GASKET


    1. A0159S8E01

      Using a screwdriver, pry out the ventilation pipe gasket.

      Table 33. Text in Illustration
      *1 Protective Tape
      Tip:

      Tape the screwdriver tip before use.

  57. Click here

    REMOVE NO. 1 HEAT EXCHANGER COVER


    1. A01597Q

      Remove the 12 bolts and 2 nuts.

      Table 34. Text in Illustration
      A015DIT Bolt
      A015CC1 Nut
    2. A0157ELE01

      Remove the No. 1 heat exchanger cover by prying between the No. 1 heat exchanger cover and cylinder block with a screwdriver.

      Table 35. Text in Illustration
      *1 Protective Tape
      Tip:

      Tape the screwdriver tip before use.

  58. Click here

    REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A0156MV

      Remove the 14 bolts and 2 nuts.

      Table 36. 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.

  59. Click here

    REMOVE NO. 1 OIL PAN SUB-ASSEMBLY


    1. A0157QV

      Remove the 14 bolts and 2 nuts.

      Table 37. 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. A01563VE01

      Remove the No. 1 oil pan by prying between the No. 1 oil pan and cylinder block with a screwdriver.

      Table 38. Text in Illustration
      *a for LH Side
      *b for RH Side
      Note:

      Be careful not to damage the contact surfaces of the cylinder block and No. 1 oil pan.

      Tip:

      Tape the screwdriver tip before use.

  60. Click here

    REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A0157P3

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

  61. Click here

    REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A0158RC

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

  62. Click here

    REMOVE REAR ENGINE OIL SEAL RETAINER


    1. A015CJC

      Remove the 6 bolts and rear engine oil seal retainer.

    2. A015BCZ

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

      Tip:

      Tape the screwdriver tip before use.

  63. Click here

    REMOVE REAR CRANKSHAFT OIL SEAL


    1. A015E46E05

      Place the rear engine oil seal retainer on wooden blocks.

      Table 39. Text in Illustration
      *1 Wooden Block

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

  64. Click here

    REMOVE OIL DRAIN PIPE SUB-ASSEMBLY


    1. A0157E2

      Remove the bolt and oil drain pipe.

    2. Remove the O-ring.

  65. Click here

    REMOVE RING PIN

    Note:

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

  66. Click here

    REMOVE STUD BOLT

    Note:

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