ENGINE UNIT DISASSEMBLY

  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

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

  2. REMOVE SPARK PLUG

    1. Remove the 6 spark plugs.

      A011SUJ

  3. REMOVE OIL PAN DRAIN PLUG

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

      A011R6G

  4. REMOVE VENTILATION VALVE SUB-ASSEMBLY

    1. Remove the ventilation valve sub-assembly.

      A011S8Q

  5. REMOVE VVT SENSOR

    1. Disconnect the 4 sensor connectors.

    2. Remove the 4 bolts and 4 sensors.

      A011RR8E02
      Text in Illustration
      *a for Bank 1
      *b for Bank 2
      *c for Intake Side
      *d for Exhaust Side

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    1. Disconnect the 4 oil control valve connectors.

    2. Remove the 4 bolts and 4 oil control valves.

      A011TGBE01
      Text in Illustration
      *a for Intake Side
      *b for Exhaust Side
      *c for Bank 2
      *d for Bank 1

    3. Remove the O-ring from each oil control valve.

      A011RTBE06
      Text in Illustration
      *1 O-ring

  7. REMOVE CRANK POSITION SENSOR

    1. Disconnect the crank position sensor connector.

      A011TZ2

    2. Remove the bolt and crank position sensor.

  8. REMOVE NO. 1 OIL PIPE

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

      A011UO9E02
      Text in Illustration
      *1 Oil Pipe Union

    2. Remove the oil control valve filter LH and gaskets.

  9. REMOVE OIL PIPE

    1. Remove the bolt.

      A011TX4E04
      Text in Illustration
      *1 Oil Pipe Union
      *2 Bolt

    2. Remove the 2 oil pipe unions and oil pipe.

    3. Remove the oil control valve filter RH and gaskets.

  10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

    A011UCUE07
    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.

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

  11. REMOVE OIL FILTER CAP ASSEMBLY

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

      A011TMCE01
      Text in Illustration
      *1 Pipe
      *2 Hose

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

      A011TKG

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

      A011TWXE02
      Text in Illustration
      *1 Cap
      *2 O-ring
      *3 Pipe

      Note

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

      Tech Tips

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

    4. Make sure that oil is completely drained, and remove the pipe and O-ring.

      A011S6D

      Tech Tips

      Be sure to turn the pipe in the direction of the arrow to remove it.

    5. Using SST, remove the oil filter cap.

      A011U4KE01
      SST
      09228-06501

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

      A011S6AE06
      Text in Illustration
      *1 Oil Filter Element
      *2 Oil Filter Cap
      *3 O-ring

      Note

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

  12. REMOVE CRANKSHAFT PULLEY

    1. Using SST, loosen the crankshaft pulley bolt.

      A011SYME03
      SST
      09213-70011   ( 09213-70020 )
      09330-00021
      Text in Illustration
      *a Hold
      A011T1X Turn

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

      A011UNGE01
      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
      Text in Illustration
      *a Hold
      A011T1X Turn

    3. Remove the pulley set key from the crankshaft.

      A011RDQ

  13. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    1. Remove the bolt and engine oil level dipstick guide.

      A011V0X

    2. Remove the O-ring.

      A011RZP

  14. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH

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

      A011S67

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

  15. REMOVE WATER INLET HOUSING

    1. Remove the 2 nuts, water inlet and thermostat.

      A011V18

    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. Remove the drain cock plug.

      A011T8LE04
      Text in Illustration
      *1 Nut
      *2 Bolt

    6. Remove the drain cock assembly.

    7. Remove the 2 bolts, nut, and water inlet housing.

    8. Remove the 2 O-rings.

      A011RT6

  16. REMOVE WATER OUTLET

    1. Remove the 2 bolts, 4 nuts and water outlet.

      A011TTXE02
      Text in Illustration
      *1 Nut
      *2 Bolt

    2. Remove the 2 gaskets and O-ring.

      A011TD8

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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

      A011SZ8

    2. Remove the 3 gaskets.

      A011UEF

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

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

      A011ROYE05
      Text in Illustration
      *1 Baffle Plate

      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. Remove the 3 gaskets.

      A011R8B

  19. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

    1. Remove the 16 bolts and 2 nuts.

      A011RRCE02
      Text in Illustration
      *1 Nut

    2. 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.

      A011SPM

      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.

  20. REMOVE OIL STRAINER SUB-ASSEMBLY

    1. Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.

      A011QUQE03
      Text in Illustration
      *1 Bolt
      *2 Nut

    2. Using an E6 "TORX" socket wrench, remove the 2 stud bolts.

  21. REMOVE OIL PAN SUB-ASSEMBLY

    1. Remove the 16 bolts and 2 nuts.

      A011TEHE03
      Text in Illustration
      *1 Nut

      Tech Tips

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

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

      A011UGBE02
      Text in Illustration
      *1 Protective Tape

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

    3. Remove the 2 O-rings.

      A011SSO

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

  22. REMOVE NO. 1 OIL PAN BAFFLE PLATE

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

      A011S9D

  23. REMOVE ENGINE REAR OIL SEAL RETAINER

    1. Remove the 6 bolts.

      A011TPM

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

      A011SB6E02
      Text in Illustration
      *1 Protective Tape
      A011T1X Pry

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  24. REMOVE ENGINE REAR OIL SEAL

    1. Place the engine rear oil seal retainer on wooden blocks.

      A011QYKE07
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  25. REMOVE ENGINE WATER PUMP ASSEMBLY

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

      A011UX5

  26. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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

      A011RD1E02
      Text in Illustration
      *1 Nut

    2. Remove the timing chain cover sub-assembly by prying between the timing chain cover and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver.

      A011TFME04
      Text in Illustration
      *1 Protective Tape

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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

    4. Remove the gasket.

      A011SVZ

  27. REMOVE TIMING CHAIN CASE OIL SEAL

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

      A011U74E05
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

      Tech Tips

      Tape the screwdriver tip before use.

  28. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. Temporarily tighten the pulley set bolt.

    2. Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression).

      A011ULGE02
      Text in Illustration
      *1 Sensor Plate
      *a Center Line
      *b Timing Mark

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

      A011TBVE07
      Text in Illustration
      *a Timing Mark

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

  29. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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

      A011TTVE06
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate
      *3 Pin

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

      A011RF8

  30. REMOVE CHAIN TENSIONER SLIPPER

    1. Remove the chain tensioner slipper.

  31. REMOVE CHAIN SUB-ASSEMBLY

    1. Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket.

      A011SZGE02
      Text in Illustration
      *1 Sensor Plate
      *a Center Line
      *b Timing Mark

    2. Remove the pulley set bolt.

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

      A011TBP

    4. 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.

      A011S4VE13
      Text in Illustration
      *a for Bank 1

    5. Remove the chain sub-assembly.

  32. REMOVE IDLE SPROCKET ASSEMBLY

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

      A011SJY

  33. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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

      A011TMX

  34. REMOVE NO. 2 CHAIN VIBRATION DAMPER

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

  35. REMOVE CRANKSHAFT TIMING SPROCKET

    1. Remove the crankshaft timing sprocket from the crankshaft.

      A011TPZ

    2. Remove the 2 keys from the crankshaft.

  36. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

    1. 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.

      A011T8DE08
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

    2. Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

      A011R83E06
      Text in Illustration
      *a Turn
      *b Hold
      SST
      09922-10010

      Note

      • Be careful not to damage the cylinder head 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 assembly together with the No. 2 chain.

  37. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

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

      A011S6T

  38. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

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

      A011THTE08
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

      A011SBXE03

    3. Uniformly loosen and remove the 12 bearing cap bolts in several steps and in the sequence shown in the illustration.

      A011QSGE01

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 5 camshaft bearing caps.

  39. REMOVE CAMSHAFT

    1. Remove the camshaft.

  40. REMOVE NO. 2 CAMSHAFT

    1. Remove the No. 2 camshaft.

  41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

    1. Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver.

      A011RQ0E02
      Text in Illustration
      *1 Protective Tape

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  42. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

    1. 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.

      A011SKXE07
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

    2. Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

      A011SD0E06
      Text in Illustration
      *a Turn
      *b Hold
      SST
      09922-10010

      Note

      • Be careful not to damage the cylinder head 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 together with the No. 2 chain.

  43. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

    1. Remove the bolt and No. 3 chain tensioner assembly.

      A011UFM

  44. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

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

      A011TKTE06
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

      A011V9BE03

    3. Uniformly loosen and remove the 13 bearing cap bolts in several steps and in the sequence shown in the illustration.

      A011UXVE01

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 5 camshaft bearing caps.

  45. REMOVE NO. 3 CAMSHAFT

    1. Remove the No. 3 camshaft.

  46. REMOVE NO. 4 CAMSHAFT

    1. Remove the No. 4 camshaft.

  47. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

    1. Remove the camshaft housing sub-assembly LH by prying between the cylinder head and camshaft housing sub-assembly LH with a screwdriver.

      A011TIOE02
      Text in Illustration
      *1 Protective Tape

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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

    1. Remove the 24 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  49. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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

      Tech Tips

      Arrange the removed parts in the correct order.

  50. REMOVE VALVE STEM CAP

    1. Remove the 24 valve stem caps.

  51. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

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

      A011QSOE01

      Note

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

      • Cylinder head 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.

  52. REMOVE CYLINDER HEAD GASKET RH

    1. Remove the cylinder head gasket RH.

  53. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

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

      A011QYOE01

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

      A011U8IE01

      Note

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

      • Cylinder head 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.

  54. REMOVE CYLINDER HEAD GASKET LH

    1. Remove the cylinder head gasket LH.

  55. REMOVE WATER INLET PIPE

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

    2. Remove the 2 bolts and water inlet pipe.

      A011TIG