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. A01CC7G

      Remove the 6 spark plugs.

  3. REMOVE OIL PAN DRAIN PLUG


    1. A01CCRX

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

  4. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A01CAKM

      Remove the ventilation valve sub-assembly.

  5. REMOVE CAMSHAFT POSITION SENSOR


    1. Disconnect the 4 sensor connectors.

    2. A01CFD0E01

      Remove the 4 bolts and 4 sensors.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01CFTD

      Disconnect the wire harness clamp.

    2. Disconnect the 4 oil control valve connectors.

    3. A01CCE3E01

      Remove the 4 bolts and 4 oil control valves.

    4. A01CFM8E05

      Remove the O-ring from each oil control valve.

  7. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01CCPN

      Disconnect the crank position sensor connector.

    2. Remove the bolt and crank position sensor.

  8. REMOVE NO. 1 OIL PIPE


    1. A01CEVKE01

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

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

  9. REMOVE OIL PIPE


    1. A01CDJBE01

      Remove the 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


    1. A01CEDLE05

      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 ELEMENT


    1. A01CCLD

      Remove the drain plug.

      Note

      Do not remove the O-ring from the oil filter cap.

    2. A01CBI9E04

      Connect the hose to the pipe.

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

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

    5. A01CBX3E01

      Using SST, remove the oil filter cap sub-assembly.

      SST
      09228-06501
    6. A01CB2QE10

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

      Note

      Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.

  12. REMOVE CRANKSHAFT PULLEY


    1. A01CFZDE02

      Using SST, loosen the crankshaft pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A01CBOUE02

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
    3. A01CBG4

      Remove the pulley set key from the crankshaft.

  13. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01CFQT

      Remove the bolt and engine oil level dipstick guide.

    2. A01CDBV

      Remove the O-ring.

  14. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A01CEZ2

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

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

    3. Using a socket wrench 8mm, remove the stud bolt.

  15. REMOVE WATER INLET HOUSING


    1. A01CC5O

      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. A01CDO5E01

      Remove the drain cock plug.

    6. Remove the drain cock assembly.

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

    8. A01CG1U

      Remove the 2 O-rings.

  16. REMOVE WATER OUTLET


    1. A01CG1NE01

      Remove the 2 bolts, 4 nuts and water outlet.

    2. A01CDCP

      Remove the 2 gaskets and O-ring.

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)


    1. A01CC28

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

    2. A01CGHZ

      Remove the 3 gaskets.

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)


    1. A01CFJ6E02

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

    2. A01CDD3

      Remove the 3 gaskets.

  19. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01CC1PE01

      Remove the 16 bolts and 2 nuts.

    2. A01CCX8

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

  20. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01CFSL

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

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

  21. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01CGHYE01

      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. A01CE0BE01

      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 and oil pan.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A01CDQF

      Remove the 2 O-rings.

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

  22. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01CFBJ

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

  23. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01CC5F

      Remove the 6 bolts.

    2. A01CGGDE01

      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.

  24. REMOVE ENGINE REAR OIL SEAL


    1. A01CBUSE04

      Place the engine rear oil seal retainer on wooden blocks.

    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 TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01CEAW

      Remove the 23 bolts and 2 nuts as shown in the illustration.

    2. A01CDSNE02

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

      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. A01CCUIE01

      Remove the gasket.

  26. REMOVE TIMING CHAIN CASE OIL SEAL


    1. A01CBJXE04

      Using a screwdriver, pry out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  27. REMOVE WATER PUMP ASSEMBLY


    1. A01CFP6

      Remove the 8 bolts, water pump assembly and water pump gasket.

  28. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily tighten the pulley set bolt.

    2. A01CAZXE06

      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. A01CEKEE02

      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.

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

  29. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01CAN9E02

      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 (0.05 in.) into the stopper plate hole.

    3. A01CB8J

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

  30. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  31. REMOVE CHAIN SUB-ASSEMBLY


    1. A01CCELE02

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

    2. Remove the pulley set bolt.

    3. A01CB86

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

    4. A01CAK1E08

      Turn the camshaft timing gear assembly on the 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.

  32. REMOVE IDLE SPROCKET ASSEMBLY


    1. A01CAQM

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

  33. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01CEMA

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

  34. REMOVE NO. 2 CHAIN VIBRATION DAMPER


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

  35. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01CEY8

      Remove the crankshaft timing sprocket from the crankshaft.

    2. Remove the 2 keys from the crankshaft.

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


    1. A01CGJGE01

      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. A01CFCNE02

      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

      Do not loosen the other 4 bolts. If any of the 4 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. A01CC08

      Remove the bolt and No. 2 chain tensioner assembly.

  38. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A01CC5QE01

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

    2. A01CDQKE03

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

    3. A01CFI8E01

      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.

  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. A01CE5JE01

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

      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. A01CFOJE01

      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. A01CGATE02

      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

      Do not loosen the other 4 bolts. If any of the 4 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. A01CAVI

      Remove the bolt and No. 3 chain tensioner assembly.

  44. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A01CC0GE01

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

    2. A01CGJLE03

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

    3. A01CBAOE01

      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.

  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. A01CF4KE01

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

      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. A01CD93E01

      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 RH.

  52. REMOVE CYLINDER HEAD GASKET RH


    1. Remove the cylinder head gasket RH.

  53. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. A01CDQ9E01

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

    2. A01CEURE01

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

    2. A01CG0A

      Remove the 2 bolts and water inlet pipe.