ENGINE UNIT DISASSEMBLY


  1. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A00XECG

      Using a 24 mm deep socket wrench, remove the oil pressure switch.

  2. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A00XFOI

      Using a 19 mm deep socket wrench, remove the sensor.

    2. Remove the gasket from the sensor.

  3. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A00XH47

      Remove the water drain cock plug from the water drain cock.

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

  4. REMOVE VVT SENSOR


    1. A00XETG

      LH:

      Remove the 2 bolts and 2 VVT sensors.

    2. A00XH0I

      RH:

      Remove the 2 bolts and 2 VVT sensors.

  5. REMOVE CRANKSHAFT POSITION SENSOR


    1. A00XJDI

      Remove the bolt and crankshaft position sensor.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH


    1. A00XK4Q

      LH:

      Remove the 2 bolts and 2 oil control valves.

    2. A00XJPR

      RH:

      Remove the 2 bolts and 2 oil control valves.

  7. REMOVE OIL FILLER CAP HOUSING


    1. A00XE1Z

      Remove the oil filler cap.

    2. Remove the 2 nuts, oil filler cap housing and gasket.

  8. REMOVE NO. 1 OIL PIPE


    1. A00XG18

      Remove the 2 oil pipe unions, oil control valve filter LH, 3 gaskets and No. 1 oil pipe.

      Note

      Do not touch the mesh when removing the oil control valve filter.

  9. REMOVE NO. 2 OIL PIPE


    1. A00XJQY

      Remove the 2 oil pipe unions, oil control valve filter RH, 3 gaskets and No. 2 oil pipe.

      Note

      Do not touch the mesh when removing the oil control valve filter.

  10. REMOVE OIL FILTER ELEMENT


    1. A00XCDRE09
      Text in Illustration
      *1 Pipe
      *2 Hose

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

    2. A00XFWB

      Remove the oil filter drain plug.

    3. A00XIN1E01
      Text in Illustration
      *1 Cap
      *2 Valve
      *3 Pipe
      *4 O-Ring
      *5 Hose

      Install the pipe to the oil filter cap.

      Tech Tips

      Use a container to catch the draining oil.

      Note

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

    4. A00XFS9

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

    5. A00XGDIE01
      Text in Illustration
      *1 Oil Filter Bracket Clip

      Using SST, remove the oil filter cap.

      SST
      09228-06501

      Note

      Do not remove the oil filter bracket clip.

    6. A00XI78E03
      Text in Illustration
      *1 O-Ring

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

      Note

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

  11. REMOVE OIL FILTER BRACKET


    1. A00XCERE01
      Text in Illustration
      *A w/ Oil Cooler
      *B w/o Oil Cooler

      Remove the 2 nuts, bolt, oil filter bracket and gasket.

  12. REMOVE WATER INLET HOUSING


    1. A00XIWT

      Disconnect the 3 water by-pass hoses.

    2. A00XGL4

      Remove the 5 bolts and water inlet housing.

    3. A00XEKW

      Remove the O-ring and gasket from the water outlet pipe and water pump.

    4. A00XDCW

      Remove the 3 water by-pass hoses.

  13. REMOVE REAR WATER BY-PASS JOINT


    1. A00XGLEE01

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

    2. Remove the O-ring from the No. 1 water outlet pipe.

  14. REMOVE SPARK PLUG


    1. Remove the 6 spark plugs.

  15. REMOVE PCV VALVE SUB-ASSEMBLY


    1. Remove the PCV valve hose.

    2. A00XJOO

      Remove the PCV valve.

  16. REMOVE CRANKSHAFT PULLEY


    1. A00XC2CE04

      Using SST, hold the crankshaft pulley and loosen the pulley bolt. Continue to loosen the bolt until only 2 or 3 threads are screwed into the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A00XDBGE02

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05031 )

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A00XJPT

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

      Tech Tips

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

    2. A00XKE2

      Remove the 3 gaskets.

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00XFR6

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

      Tech Tips

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

    2. A00XJMN

      Remove the 3 gaskets.

  19. REMOVE SPARK PLUG TUBE GASKET

    A00XGJ7

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

      Text in Illustration
      A00XHOQ Pry

    2. Remove the 6 spark plug tube gaskets.

      Tech Tips

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

  20. REMOVE ENGINE OIL LEVEL SENSOR (w/ Warmer)


    1. Disconnect the connector.

    2. A009AFP

      Remove the 4 bolts and sensor.

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

      Tech Tips

      Remove only the outer part of the gasket.

  21. REMOVE OIL PAN DRAIN PLUG


    1. Remove the drain plug and gasket.

  22. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A00XI4R

      Remove the 10 bolts and 2 nuts.

      Tech Tips

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

    2. A00XHY7E02
      Text in Illustration
      *1 Oil Pan Seal Cutter

      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.

  23. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A00XG2T

      Remove the 2 nuts, oil strainer and gasket.

  24. REMOVE OIL PAN SUB-ASSEMBLY


    1. A00XEGT

      Remove the 17 bolts and 2 nuts.

      Tech Tips

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

    2. A00XERAE01
      Text in Illustration
      *1 LH Side
      *2 RH Side
      *a Pry

      Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block as shown in the illustration.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

    3. A00XHGX

      Remove the 3 O-rings from the timing chain cover.

  25. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A00XCJ4

      Remove the 6 bolts and No. 1 oil pan baffle plate.

  26. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A00XHBSE04
      Text in Illustration
      *a Pry

      Remove the 5 bolts and 2 nuts.

    2. Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and crankshaft bearing cap.

      Tech Tips

      Tape the screwdriver tip before use.

  27. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A00XHTBE03

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

      Note

      Be careful not to damage the rear oil seal retainer.

  28. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A00XF48

      Remove the 26 bolts and the 2 nuts.

    2. A00XK7J

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

    3. A00XEZQ

      Remove the oil pump gasket from the cylinder block.

  29. REMOVE WATER PUMP ASSEMBLY


    1. A00XCDF

      Remove the 8 bolts, water pump and gasket.

  30. REMOVE FRONT CRANKSHAFT OIL SEAL


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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  31. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the pulley set bolt.

    2. A00XCE2E01
      Text in Illustration
      *1 Center Line
      *2 Timing Mark
      *3 Sensor Plate

      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. A00XF3PE01
      Text in Illustration
      *1 Timing Mark

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

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

  32. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A00XHFUE05
      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 φ1.27 mm (0.0500 in.) into the stopper plate hole.

    3. A00XDIFE02

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

  33. REMOVE CHAIN TENSIONER SLIPPER


    1. A00XCU0

      Remove the chain tensioner slipper.

  34. REMOVE NO. 1 CHAIN SUB-ASSEMBLY


    1. A00XKKAE01
      Text in Illustration
      *1 Center Line
      *2 Timing Mark
      *3 Sensor Plate

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

    2. Remove the pulley set bolt.

    3. A00XGVS

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

    4. A00XFS0E12

      Turn the camshaft timing gear assembly on bank 1 clockwise approximately 60° so that it is as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks.

    5. Remove the chain sub-assembly.

      Text in Illustration
      *A for Bank 1

  35. REMOVE NO. 1 IDLE GEAR SHAFT


    1. A00XIGH

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

  36. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A00XDN9

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

  37. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A00XC1I

      Remove the 2 No. 2 chain vibration dampers.

  38. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A00XHVUE01

      Remove the crankshaft timing sprocket.

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


    1. A00XHBJE01
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

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

    2. A00XCT3E01
      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 camshaft timing exhaust gear assembly.

      SST
      09922-10010

      Note

      Do not loosen the other 4 bolts. If any of the 4 bolts is loosened, replace the camshaft timing gear assembly and/or camshaft timing exhaust gear assembly with a new one.

    3. Remove the 2 bolts and camshaft timing gear assembly together with the No. 2 chain.

  40. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A00XGTY

      Remove the bolt and No. 2 chain tensioner assembly.

  41. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A00XCBTE06
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A00XFYRE01

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

    3. A00XF7DE01

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

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 5 camshaft bearing caps.

    5. Remove the camshaft and No. 2 camshaft.

  42. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A00XGHBE01
      Text in Illustration
      *1 Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

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


    1. A00XK4JE01
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

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

    2. A00XD14E01
      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 camshaft timing exhaust gear assembly.

      SST
      09922-10010

      Note

      Do not loosen the other 4 bolts. If any of the 4 bolts is loosened, replace the camshaft timing gear assembly and/or camshaft timing exhaust gear assembly with a new one.

    3. Remove the 2 bolts and camshaft timing gear together with the No. 2 chain.

  44. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A00XJ24

      Remove the bolt and No. 3 chain tensioner assembly.

  45. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A00XCZHE01
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A00XD0YE01

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

    3. A00XJ9AE01

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

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 5 camshaft bearing caps.

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

  46. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A00XJHCE01
      Text in Illustration
      *1 Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

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


    1. Remove the 24 valve rocker arms from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  48. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 24 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  49. REMOVE VALVE STEM CAP


    1. Remove the 24 valve stem caps from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  50. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A00K1C3E01

      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.

      Note


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

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

      Tech Tips

      Arrange the removed parts in the correct order.

    2. Remove the cylinder head sub-assembly.

  51. REMOVE CYLINDER HEAD LH


    1. A00JWFIE01

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

    2. A00JZ8OE01

      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.

      Note


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

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

      Tech Tips

      Be sure to keep the removed parts for each installation position separate.

    3. Remove the cylinder head LH.

  52. REMOVE CYLINDER HEAD GASKET

  53. REMOVE NO. 2 CYLINDER HEAD GASKET

  54. REMOVE NO. 1 WATER OUTLET PIPE


    1. A0094IQ

      Detach the 3 wire harness clamps.

    2. Remove the 2 nuts, bolt and water outlet pipe.

  55. REMOVE KNOCK SENSOR


    1. A009BP2

      Disconnect the 2 sensor connectors.

    2. Remove the 2 bolts and 2 sensors.

  56. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    A00XFNW

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

      Note

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

  57. REMOVE TAPER SCREW PLUG

    Note

    It is not necessary to remove a taper screw plug unless it is being replaced.

  58. REMOVE STRAIGHT PIN

    Note

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

  59. REMOVE RING PIN

    Note

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

  60. REMOVE STUD BOLT

    Note

    It is not necessary to remove a stud bolt unless it is being replaced.