ENGINE UNIT DISASSEMBLY

REMOVE OIL FILLER CAP SUB-ASSEMBLY
1. Remove the oil filler cap sub-assembly and oil filler gasket.
REMOVE SPARK PLUG
1. Remove the 6 spark plugs.
REMOVE OIL PAN DRAIN PLUG
1. Remove the oil pan drain plug and oil pan drain plug gasket.
REMOVE VENTILATION VALVE SUB-ASSEMBLY
1. Remove the ventilation valve sub-assembly.
REMOVE CAMSHAFT POSITION SENSOR
1. Disconnect the 4 sensor connectors.
2. Remove the 4 bolts and 4 sensors.
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Disconnect the wire harness clamp.
2. Disconnect the 4 oil control valve connectors.
3. Remove the 4 bolts and 4 oil control valves.
4. Remove the O-ring from each oil control valve.
REMOVE CRANKSHAFT POSITION SENSOR
1. Disconnect the crank position sensor connector.
2. Remove the bolt and crank position sensor.
REMOVE NO. 1 OIL PIPE
1. Text in Illustration
  
  *a Oil Pipe Union
  
  Remove the 2 oil pipe unions, gaskets and No. 1 oil pipe.
2. Remove the oil control valve filter LH and gaskets.
REMOVE OIL PIPE
1. Text in Illustration
  
  *a Oil Pipe Union
  
  *b Bolt
  
  Remove the bolt.
2. Remove the 2 oil pipe unions and oil pipe.
3. Remove the oil control valve filter RH and gaskets.
REMOVE TAPER SCREW PLUG
Tech Tips

Perform this operation only when a taper screw plug is installed.
1. Remove the taper screw plug from the cylinder block sub-assembly.
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. for Bank 1:
  1. Remove the cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.
  2. Remove the cylinder block water drain cock plug from the cylinder block water drain cock sub-assembly.
2. for Bank 2:
  
  Tech Tips
  
  Perform this operation only when a cylinder block water drain cock sub-assembly is installed.
  1. Remove the cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.
  2. Remove the cylinder block water drain cock plug from the cylinder block water drain cock sub-assembly.

Text in Illustration
*a	Oil Pipe Union

Text in Illustration
*a	Oil Pipe Union
*b	Bolt

REMOVE OIL FILTER ELEMENT

Remove the drain plug from the oil filter cap sub-assembly.

Note

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

Text in Illustration
*a	Pipe
*b	Hose
*c	O-ring

Connect the hose to the pipe.

Insert the pipe with the hose into the oil filter cap sub-assembly.
Make sure that the oil is completely drained and remove the pipe and O-ring.
Using SST, remove the oil filter cap sub-assembly.

SST

09228-06501
Text in Illustration

*1 Oil Filter Element

*a O-ring

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.

REMOVE CRANKSHAFT PULLEY
1. Using SST, loosen the crankshaft pulley bolt.
  
  SST
  
  09213-70011 ( 09213-70020 )
  
  09330-00021
2. Using SST, remove the crankshaft pulley bolt and crankshaft pulley.
  
  SST
  
  09950-50013 ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
3. Remove the pulley set key from the crankshaft.
REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE
1. Remove the bolt and engine oil level dipstick guide.
2. Remove the O-ring.
REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH
1. Remove the 6 bolts and No. 1 front engine mounting bracket LH.
2. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.

Text in Illustration
*1	Oil Filter Element
*a	O-ring

REMOVE WATER INLET HOUSING

Remove the 2 nuts, water inlet and thermostat.
Remove the gasket.
Remove the 2 stud bolts.
Separate the No. 1 water by-pass hose from the water inlet housing.

Text in Illustration
*1	Drain Cock Plug
*2	Drain Cock Assembly
*a	Bolt
*b	Nut

Remove the drain cock plug.

Remove the drain cock assembly from the water inlet housing.
Remove the 2 bolts, nut and water inlet housing.
Remove the 2 O-rings.

REMOVE WATER OUTLET
1. Text in Illustration
  
  *a Nut
  
  *b Bolt
  
  Remove the 2 bolts, 4 nuts and water outlet.
2. Remove the 2 gaskets and O-ring.
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
1. Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.
2. Remove the 3 gaskets.
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
1. Text in Illustration
  
  *a Baffle Plate
  
  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. Remove the 3 gaskets.
REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
1. Text in Illustration
  
  *a Nut
  
  Remove the 16 bolts and 2 nuts.
2. Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and No. 2 oil pan sub-assembly. 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 pan sub-assembly and No. 2 oil pan sub-assembly.
3. Using an E6 "TORX" socket wrench, remove the 2 stud bolts.
REMOVE OIL STRAINER SUB-ASSEMBLY
1. Text in Illustration
  
  *a Bolt
  
  *b Nut
  
  Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.
2. Using an E6 "TORX" socket wrench, remove the 2 stud bolts.
REMOVE OIL PAN SUB-ASSEMBLY
1. Text in Illustration
  
  *a Nut
  
  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. Text in Illustration
  
  *a Protective Tape
  
  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 sub-assembly and oil pan sub-assembly.
  
  Tech Tips
  
  Tape the screwdriver tip before use.
3. Remove the 2 O-rings.
4. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
REMOVE NO. 1 OIL PAN BAFFLE PLATE
1. Remove the 7 bolts and No. 1 oil pan baffle plate.
REMOVE ENGINE REAR OIL SEAL RETAINER
1. Remove the 6 bolts.
2. Text in Illustration
  
  *a Protective Tape
  
  Pry
  
  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.
REMOVE ENGINE REAR OIL SEAL
1. Text in Illustration
  
  *a Wooden Block
  
  *b Protective Tape
  
  Place the engine rear oil seal retainer on wooden blocks.
2. Using a screwdriver and a hammer, tap out the engine rear oil seal.
  
  Note
  
  Be careful not to damage the engine rear oil seal retainer.
  
  Tech Tips
  
  Tape the screwdriver tip before use.
REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
1. Remove the 23 bolts and 2 nuts as shown in the illustration.
2. 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. Remove the gasket.
REMOVE TIMING CHAIN CASE OIL SEAL
1. Using a screwdriver, pry out the oil seal.
  
  Tech Tips
  
  Tape the screwdriver tip before use.
REMOVE WATER PUMP ASSEMBLY
1. Remove the 8 bolts, water pump assembly and water pump gasket.

Text in Illustration
*a	Nut
*b	Bolt

Text in Illustration
*a	Baffle Plate

Text in Illustration
*a	Nut

Text in Illustration
*a	Bolt
*b	Nut

Text in Illustration
*a	Nut

Text in Illustration
*a	Protective Tape

Text in Illustration
*a	Protective Tape
	Pry

Text in Illustration
*a	Wooden Block
*b	Protective Tape

SET NO. 1 CYLINDER TO TDC/COMPRESSION

Temporarily tighten the pulley set bolt.

Text in Illustration
*a	Center Line
*b	Timing Mark
*c	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).

Text in Illustration

*a Timing Mark

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.

Text in Illustration
*a	Timing Mark

REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

Text in Illustration
*a	Plunger
*b	Stopper Plate
*c	Hexagon Wrench

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

Move the stopper plate downward to set the lock, and insert hexagon wrench into the stopper plate hole.
Remove the 2 bolts and No. 1 chain tensioner assembly.

REMOVE CHAIN TENSIONER SLIPPER
1. Remove the chain tensioner slipper.
REMOVE CHAIN SUB-ASSEMBLY
1. Turn the crankshaft counterclockwise 10° to loosen the chain sub-assembly of the crankshaft timing sprocket.
2. Remove the pulley set bolt.
3. Remove the chain sub-assembly from the crankshaft timing sprocket and place it on the crankshaft.
4. Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks.
5. Remove the chain sub-assembly.
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.
REMOVE NO. 1 CHAIN VIBRATION DAMPER
1. Remove the 2 bolts and No. 1 chain vibration damper.
REMOVE NO. 2 CHAIN VIBRATION DAMPER
1. Remove the 2 No. 2 chain vibration dampers.
REMOVE CRANKSHAFT TIMING SPROCKET
1. Remove the crankshaft timing sprocket from the crankshaft.
2. Remove the 2 keys from the crankshaft.
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.
2. 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.
REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
1. Remove the bolt and No. 2 chain tensioner assembly.
REMOVE CAMSHAFT BEARING CAP (for Bank 1)
1. Check that the camshafts are positioned as shown in the illustration.
2. Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration.
3. 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.
REMOVE CAMSHAFT
1. Remove the camshaft.
REMOVE NO. 2 CAMSHAFT
1. Remove the No. 2 camshaft.
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.
  
  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.
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.
2. 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.
REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
1. Remove the bolt and No. 3 chain tensioner assembly.
REMOVE CAMSHAFT BEARING CAP (for Bank 2)
1. Check that the camshafts are positioned as shown in the illustration.
2. Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration.
3. 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.
REMOVE NO. 3 CAMSHAFT
1. Remove the No. 3 camshaft.
REMOVE NO. 4 CAMSHAFT
1. Remove the No. 4 camshaft.
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.
  
  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.
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.
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.
REMOVE VALVE STEM CAP
1. Remove the 24 valve stem caps.
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.
  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.
REMOVE CYLINDER HEAD GASKET RH
1. Remove the cylinder head gasket RH.
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.
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.
  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.
REMOVE CYLINDER HEAD GASKET LH
1. Remove the cylinder head gasket LH.
REMOVE WATER INLET PIPE
1. Slide the clip and separate the No. 1 water by-pass hose.
  
  Remove the 2 bolts and water inlet pipe.