ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILTER ELEMENT


    1. A01EN3EE10
      Text in Illustration
      *1 Pipe
      *2 Hose

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

    2. A01ESLO

      Remove the oil filter drain plug.

    3. A01EQAOE01
      Text in Illustration
      *1 Cap
      *2 Valve
      *3 Pipe
      *4 O-Ring
      *5 Hose

      Install the pipe to the oil filter cap.

      Note

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

      Tech Tips

      Use a container to catch the draining oil.

    4. A01EQTR

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

    5. A01EOS0E02
      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. A01ERDTE02
      Text in Illustration
      *1 Oil Filter Element
      *2 O-Ring

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

      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. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY


    1. A01EN3Y

      Disconnect the oil pressure sender gauge connector.

    2. A01ERH7

      Remove the oil pressure sender gauge.

  3. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY


    1. A01EORI

      Remove the 2 bolts, 2 nuts and filter bracket.

    2. A01EOY3

      Remove the 2 O-rings.

  4. REMOVE CRANKSHAFT PULLEY


    1. A01ESGAE03
      Text in Illustration
      *a Hold
      A01EO1M Turn

      Using SST, remove the crankshaft pulley set bolt.

      SST
      09213-70011
      09330-00021

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

    3. A01EOT7E02
      Text in Illustration
      *a Hold
      A01EO1M Turn

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05011 )

  5. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap.

    2. Remove the gasket from the oil filler cap.

  6. REMOVE OIL FILLER CAP HOUSING


    1. A01EOAK

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

  7. REMOVE SPARK PLUG


    1. Using a 16 mm plug wrench, remove the 8 spark plugs.

  8. REMOVE KNOCK SENSOR


    1. A01ENE1

      Disconnect the 4 knock sensor connectors.

    2. Remove the 4 bolts and 4 knock sensors.

  9. REMOVE VVT SENSOR


    1. A01EQM5E05
      Text in Illustration
      *A for Bank 2
      *B for Bank 1

      Disconnect the 4 VVT sensor connectors.

    2. Remove the 4 bolts and 4 VVT sensors.

  10. REMOVE CAMSHAFT POSITION SENSOR


    1. A01ERMU

      Disconnect the camshaft position sensor connector.

    2. Remove the bolt and camshaft position sensor.

  11. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR


    1. A01ESJI

      Remove the 2 bolts and crankshaft position sensor protector.

  12. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01ERH1

      Disconnect the crankshaft position sensor connector.

    2. Remove the bolt and crankshaft position sensor.

  13. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01ERQD

      for Bank 1:

      Remove the 2 bolts and 2 camshaft oil control valves.

    2. A01EP23

      for Bank 2:

      Remove the 2 bolts and 2 camshaft oil control valves.

  14. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A01ES17E03
      Text in Illustration
      *A for LH Side
      *B for RH Side

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

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

  15. REMOVE WATER INLET HOUSING


    1. A01ENSF

      Remove the 3 bolts and water inlet housing.

    2. Remove the gasket from the engine water pump.

  16. REMOVE FRONT WATER BY-PASS JOINT


    1. A01EP4B

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

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01EQ6Q

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

      Tech Tips

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

    2. A01EN8B

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

      Text in Illustration
      A01EP0Y Gasket

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A01EQKA

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

      Tech Tips

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

    2. A01EQTT

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

      Text in Illustration
      A01EP0Y Gasket

  19. REMOVE OIL CONTROL VALVE FILTER


    1. A01EN4OE02
      Text in Illustration
      *1 Cylinder Head Cover Spacer
      *2 Gasket
      *3 Oil Control Valve Filter

      for Bank 1:

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

    2. A01EMVBE02
      Text in Illustration
      *1 Cylinder Head Cover Spacer
      *2 Gasket
      *3 Oil Control Valve Filter

      for Bank 2:

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

  20. REMOVE SPARK PLUG TUBE GASKET


    1. A01EO31E01
      Text in Illustration
      *1 Ventilation Baffle Plate Claw
      *2 Protective Tape

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

    2. Using a screwdriver, pry out the gaskets.

      Note

      Be careful not to damage the cylinder head cover.

      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.

      • Tape the screwdriver tip before use.

  21. REMOVE ENGINE OIL LEVEL SENSOR


    1. Disconnect the oil level sensor connector.

    2. A01EQJU

      Remove the 4 bolts and oil level sensor.

    3. A01ESJZE01
      Text in Illustration
      *1 Cutting Position
      *2 Supply Part

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

      Tech Tips

      Remove the only the outer part of the gasket.

  22. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01ESLZ

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

  23. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01EQCV

      Remove the 26 bolts and nut shown in the illustration.

    2. A01ES6A

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

      Text in Illustration
      A01EPFF Protective Tape

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

    3. A01EQRF

      Remove the gasket from the cylinder block.

    4. A01EP7J

      Remove the O-ring from the oil pan.

  24. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01ESEV

      Remove the 8 bolts, engine water pump and gasket.

  25. REMOVE WATER INLET PIPE


    1. A01ES9T

      Remove the water inlet pipe.

    2. Remove the 2 O-rings from the water inlet pipe.

  26. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. Place the timing chain cover on wooden blocks.

    2. A01EP16E02
      Text in Illustration
      *1 Wooden Block
      *2 Protective Tape

      Place the oil pump on a wooden block.

    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.

      Tech Tips

      Tape the screwdriver tip before use.

  27. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the pulley set bolt.

    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

      Tech Tips

      If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

      A01EOAJE02
      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. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH


    1. A01ERPRE02
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

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

    2. A01ENERE02
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate
      *3 Hexagon Wrench

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

    3. A01EPB2

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

  29. REMOVE CHAIN TENSIONER SLIPPER LH

    A01ENMQ

  30. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH


    1. A01EP74

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

  31. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH


    1. A01EOIIE02
      Text in Illustration
      *1 Pin
      *2 Plunger
      *3 No. 3 Chain Tensioner
      *a Push

      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.

    2. A01ENWRE02
      Text in Illustration
      *a Hold
      A01EO1M Turn

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

      Note


      • Be careful not to damage the cylinder head with the wrench.

      • Do not disassemble the camshaft timing gear.

    3. A01EON7E02
      Text in Illustration
      *a Hold
      A01EO1M Turn

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

      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. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01EQ88

      Remove the 2 bolts and No. 3 chain tensioner.

  33. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH


    1. A01EON4E02
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

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

    2. A01EPJ3E02
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate
      *3 Hexagon Wrench

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

    3. A01ERAW

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

  34. REMOVE CHAIN TENSIONER SLIPPER RH

    A01ENRQ

  35. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH


    1. A01ESCG

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

  36. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH


    1. A01EPC8E02
      Text in Illustration
      *1 Pin
      *2 Plunger
      *3 No. 2 Chain Tensioner
      *a Push

      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.

    2. A01ERP3E02
      Text in Illustration
      *a Hold
      A01EO1M Turn

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

      Note


      • Be careful not to damage the cylinder head with the wrench.

      • Do not disassemble the camshaft timing gear.

    3. A01ER65E02
      Text in Illustration
      *a Hold
      A01EO1M Turn

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

      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. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01EQ3O

      Remove the 2 bolts and No. 2 chain tensioner.

  38. REMOVE CRANKSHAFT TIMING GEAR KEY


    1. A01EP4P

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

  39. REMOVE CAMSHAFT BEARING CAP LH


    1. A01EO2HE02
      Text in Illustration
      *A for Intake Side
      *B for Exhaust Side
      *1 Knock Pin

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

    2. A01EQ2OE01

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

    3. A01EQHFE01

      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.

      Tech Tips

      Arrange the removed parts in the correct order.

  40. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY


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

  41. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY


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

  42. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01ENGLE01
      Text in Illustration
      *1 Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  43. REMOVE CAMSHAFT BEARING CAP RH


    1. A01EPHJE02
      Text in Illustration
      *A for Exhaust Side
      *B for Intake Side
      *1 Knock Pin

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

    2. A01EQ1SE05

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

    3. A01EPT7E04

      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.

      Tech Tips

      Arrange the removed parts in the correct order.

  44. REMOVE NO. 1 CAMSHAFT SUB-ASSEMBLY


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

  45. REMOVE NO. 2 CAMSHAFT SUB-ASSEMBLY


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

  46. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01ESERE01
      Text in Illustration
      *1 Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. Remove the 32 No. 1 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 32 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 32 valve stem caps from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  50. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. A01EP6EE07

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

    2. A01ER4XE07

      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.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

    3. Remove the cylinder head LH.

  51. REMOVE NO. 2 CYLINDER HEAD GASKET

  52. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01EQ0ME06

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

    2. A01EQYGE05

      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.

      Tech Tips

      Be sure to arrange the removed parts for each installation position separately.

    3. Remove the cylinder head.

  53. REMOVE CYLINDER HEAD GASKET

  54. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01EQSP

      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. REMOVE OIL RETURN PIPE GASKET


    1. A01EO6OE01
      Text in Illustration
      *1 Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

  56. REMOVE VENTILATION PIPE GASKET


    1. A01ESJ7E01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, pry out the ventilation pipe gasket.

      Tech Tips

      Tape the screwdriver tip before use.

  57. REMOVE NO. 1 HEAT EXCHANGER COVER


    1. A01EQFU

      Remove the 12 bolts and 2 nuts.

      Text in Illustration
      A01EO1M Bolt
      A01ER4J Nut
    2. A01ES7EE01
      Text in Illustration
      *1 Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

  58. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01ESG1

      Remove the 14 bolts and 2 nuts.

      Text in Illustration
      A01EO1M Bolt
      A01ER4J Nut
    2. A01EPEX

      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. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY


    1. A01EPDN

      Remove the 14 bolts and 2 nuts.

      Text in Illustration
      A01EO1M Bolt
      A01ER4J Nut

      Tech Tips

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

    2. A01EMV3E01
      Text in Illustration
      *a for LH Side
      *b for RH Side

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  60. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01ER30

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

  61. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01EPQF

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

  62. REMOVE REAR ENGINE OIL SEAL RETAINER


    1. A01EPP9

      Remove the 6 bolts and rear engine oil seal retainer.

    2. A01ESBU

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

      Tech Tips

      Tape the screwdriver tip before use.

  63. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A01EP5YE05
      Text in Illustration
      *1 Wooden Block

      Place the rear engine oil seal retainer on wooden blocks.

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

  64. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY


    1. A01EMZC

      Remove the bolt and oil drain pipe.

    2. Remove the O-ring.

  65. REMOVE RING PIN

    Note

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

  66. REMOVE STUD BOLT

    Note

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