ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY


    1. A01EN3Y

      Disconnect the sender gauge connector.

    2. A01ERH7

      Remove the oil pressure sender gauge.

  2. REMOVE OIL FILTER ELEMENT


    1. A01EN3EE04

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

    2. A01ERUC

      Remove the oil filter drain plug.

    3. A01ESLDE01

      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. A01EQ1Z

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

    5. A01EQ0PE02

      Using SST, remove the oil filter cap.

      SST
      09228-06501

      Note

      Do not remove the oil filter bracket clip.

    6. A01ESHVE02

      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.

  3. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)


    1. A01ESNS

      Remove the 2 nuts and bracket.

    2. Disconnect the ground wire from the cylinder block.

  4. REMOVE OIL FILTER BRACKET (w/ Oil Cooler)


    1. A01EORI

      Remove the 2 bolts, 2 nuts and filter bracket.

    2. A01EOY3

      Remove the 2 O-rings.

  5. REMOVE OIL FILTER BRACKET (w/o Oil Cooler)


    1. A01EREE

      Remove the 2 bolts, 2 nuts and oil filter bracket.

    2. A01EOY3

      Remove the 2 O-rings.

  6. REMOVE OIL FILLER CAP SUB-ASSEMBLY

  7. REMOVE OIL FILLER CAP HOUSING


    1. A01EN2L

      Remove the 2 bolts, filler cap housing and gasket.

  8. REMOVE SPARK PLUG


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

  9. REMOVE VVT SENSOR


    1. A01EP5P

      LH:

      Remove the 2 bolts and 2 VVT sensors.

    2. A01EO3Z

      RH:

      Remove the 2 bolts and 2 VVT sensors.

  10. REMOVE CAMSHAFT POSITION SENSOR


    1. A01EPQC

      Remove the bolt and camshaft position sensor.

  11. REMOVE CRANK POSITION SENSOR PROTECTOR

    A01ER93

    1. Remove the 2 bolts and sensor protector.

  12. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01EO1R

      Remove the bolt and crankshaft position sensor.

  13. REMOVE CAMSHAFT OIL CONTROL VALVE ASSEMBLY


    1. A01ENNW

      LH:

      Remove the 2 bolts and 2 oil control valves.

    2. A01EOYZ

      RH:

      Remove the 2 bolts and 2 oil control valves.

  14. REMOVE WATER PUMP PULLEY


    1. A01ENNRE01

      Using SST, hold the water pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Remove the 4 bolts and water pump pulley.

  15. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A01EPW9

      Remove the bolt and idler pulley.

  16. REMOVE FLUID COUPLING BRACKET


    1. A01ENCD

      Remove the 4 bolts and fluid coupling bracket.

  17. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01ESLZ

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

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01ERR8

      Remove the 14 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. A01ENO4

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

  19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A01EOYL

      Remove the bolt and noise filter.

    2. A01EQUU

      Remove the 14 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.

    3. A01ENCR

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

  20. REMOVE OIL CONTROL VALVE FILTER

    A01EN4OE01

    1. LH:

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

    2. A01EMVBE01

      RH:

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

  21. REMOVE SPARK PLUG TUBE GASKET

    A01EQFDE01

    1. 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.

      Tech Tips

      Tape the screwdriver tip before use.

      Note


      • Be careful not to damage the cylinder head cover.

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

  22. REMOVE CRANKSHAFT PULLEY


    1. A01ESGAE02

      Using SST, loosen the crankshaft pulley set bolt until 2 or 3 threads are engaged.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A01ERSRE01

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

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

  23. REMOVE WATER PUMP ASSEMBLY


    1. A01EN8C

      Remove the 8 bolts, water pump and gasket.

  24. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01EQA2E01

      Remove the 28 bolts and nut shown in the illustration.

    2. A01ESI8

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

      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. A01EQ7O

      Remove the oil pump gasket from the cylinder block.

    4. A01EP7J

      Remove the O-ring from the oil pan.

  25. REMOVE WATER INLET PIPE


    1. A01EPYT

      Remove the water inlet pipe.

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

  26. REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A01EQRAE01

      Place the timing chain cover on wooden blocks.

    2. 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.

  27. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing sprocket 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.

      A01ES9FE01

  28. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH


    1. A01ENKQE01

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

    2. A01EQGLE01

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

    3. A01EPGO

      Remove the 2 bolts, chain tensioner and gasket.

  29. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

    A01EP8R

  30. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH

    A01EPSC

    1. Remove the 2 bolts and chain vibration damper.

  31. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH

    A01ESA5E01

    1. While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

    2. A01EOF9E01

      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. A01ESCOE01

      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.

    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

    A01EQM0E01

    1. Remove the 2 bolts and chain tensioner.

  33. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH


    1. A01EQK9E01

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

    2. A01EQNSE01

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

    3. A01EN7X

      Remove the 2 bolts and chain tensioner.

  34. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

    A01ERPK

  35. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH

    A01ESIK

    1. Remove the 2 bolts and vibration damper.

  36. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH

    A01EO0BE01

    1. While raising up the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

    2. A01EN2KE01

      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. A01ES6KE01

      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.

    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

    A01EQI7E01

    1. Remove the 2 bolts and chain tensioner.

  38. REMOVE CRANKSHAFT TIMING GEAR KEY

    A01EQ5D

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

  39. REMOVE CAMSHAFT BEARING CAP LH


    1. A01ENA5E02

      Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

    2. A01EPQME03

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

    3. A01EMVPE03

      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 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

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

      Tech Tips

      Arrange the removed parts in the correct order.

  40. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01ENOU

      Remove the camshaft housing by prying between the cylinder head and camshaft housing 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.

  41. REMOVE CAMSHAFT BEARING CAP RH


    1. A01ERXJE02

      Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

    2. A01EQ1SE03

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

    3. A01EPT7E03

      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 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

    5. Remove the No. 1 and No. 2 camshafts.

      Tech Tips

      Arrange the removed parts in the correct order.

  42. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01EOQF

      Remove the camshaft housing by prying between the cylinder head and camshaft housing 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.

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


    1. Remove the 32 valve rocker arms from the cylinder heads.

      Tech Tips

      Arrange the removed parts in the correct order.

  44. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 32 valve lash adjusters from the cylinder heads.

      Tech Tips

      Arrange the removed parts in the correct order.

  45. REMOVE VALVE STEM CAP


    1. Remove the 32 valve stem caps from the cylinder heads.

      Tech Tips

      Arrange the removed parts in the correct order.

  46. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. A01EP6EE05

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

    2. A01ER4XE05

      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.

      Tech Tips

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

      Note


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

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

    3. Remove the cylinder head and gasket.

  47. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH


    1. A01EQ0ME04

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

    2. A01EQYGE03

      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.

      Tech Tips

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

      Note


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

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

    3. Remove the cylinder head and gasket.

  48. REMOVE CYLINDER BLOCK WATER JACKET SPACER

    A01ENIW

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

      Note

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

  49. REMOVE VENTILATION PIPE GASKET


    1. A01EOI8

      Using a screwdriver, pry out the ventilation pipe gasket.

      Tech Tips

      Tape the screwdriver tip before use.

  50. REMOVE NO. 1 HEAT EXCHANGER COVER


    1. A01ERAME01

      Remove the 12 bolts and 2 nuts.

    2. A01EMX9

      Remove the heat exchanger by prying between the heat exchanger and cylinder block with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

  51. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. Remove the engine oil level sensor Click here.

    2. A01EPI7E01

      Remove the 14 bolts and 2 nuts.

    3. 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.

  52. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY


    1. A01EN6XE02

      Remove the 14 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. A01ENLFE02

      Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  53. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01EOGM

      Remove the 7 bolts and baffle plate.

  54. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01ENDA

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

  55. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01EPP9

      Remove the 6 bolts and oil seal retainer.

    2. A01ESBU

      Using a screwdriver, pry out the oil seal retainer.

      Tech Tips

      Tape the screwdriver tip before use.

  56. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY


    1. A01EMZC

      Remove the bolt and oil drain pipe.

    2. Remove the O-ring.

  57. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A01ESNCE01

      Place the oil seal retainer on wooden blocks.

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

  58. REMOVE RING PIN

    Note

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

  59. REMOVE STUD BOLT

    Note

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