ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE SPARK PLUG

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  2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. B0075XW

      for Bank 1:

      Remove the 2 clips and No. 1 engine cover from the cylinder head cover sub-assembly.

    2. B007658

      for Bank 2:

      Remove the clip and No. 1 engine cover from the No. 1 fuel tube sub-assembly.

  3. REMOVE NO. 1 FUEL TUBE SUB-ASSEMBLY

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  4. REMOVE VENTILATION HOSE ASSEMBLY


    1. B0073MU

      Loosen the clip and remove the ventilation hose assembly from the cylinder head cover sub-assembly LH.

  5. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

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  6. REMOVE CRANKSHAFT POSITION SENSOR

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  7. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. B0075PQ

      Remove the water drain cock plug from the cylinder block water drain cock sub-assembly.

    2. Remove the cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.

  8. REMOVE CYLINDER BLOCK WATER DRAIN COCK PLUG


    1. B0074VZ

      Remove the cylinder block water drain cock plug from the cylinder block sub-assembly.

  9. REMOVE OIL FILTER CAP ASSEMBLY

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  10. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

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  11. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler)

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  12. REMOVE CRANKSHAFT PULLEY

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  13. REMOVE WATER OUTLET SUB-ASSEMBLY


    1. B0074S3

      Remove the 2 bolts and water outlet sub-assembly.

    2. B00744Z

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

  14. REMOVE WATER INLET SUB-ASSEMBLY WITH THERMOSTAT


    1. B0075WRC01
      B0073AQ Bolt
      B0077IM Nut

      Remove the 2 bolts, nut, water inlet sub-assembly with thermostat and water inlet housing gasket.

  15. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)

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  16. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)

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  17. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)

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  18. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)

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  19. REMOVE REAR WATER BY-PASS JOINT


    1. B0075JC

      Disengage the 2 clamps and disconnect the No. 5 engine wire from the rear water by-pass joint.

    2. B0075QHC02
      B0073AQ Bolt
      B0077IM Nut

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

    3. B0076PT

      Remove the 2 water by-pass joint gaskets from the rear water by-pass joint.

    4. B0073GJ

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

  20. REMOVE VACUUM PUMP ASSEMBLY

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  21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. B0076WAC01
      *1 VVT Sensor

      Remove the 2 bolts and 2 VVT sensors from the cylinder head cover sub-assembly LH.

    2. Remove the 14 bolts and cylinder head cover sub-assembly LH from the camshaft housing sub-assembly LH.

    3. B00762G

      Remove the camshaft bearing cap oil hole gasket LH.

    4. B00768M

      Remove the 2 gaskets and cylinder head cover gasket.

  22. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B0075FQC01
      *1 VVT Sensor

      Remove the 2 bolts and 2 VVT sensors from the cylinder head cover sub-assembly.

    2. Remove the 13 bolts and cylinder head cover sub-assembly from the camshaft housing sub-assembly RH.

    3. B0076SW

      Remove the camshaft bearing cap oil hole gasket RH.

    4. B0072LI

      Remove the 2 gaskets and cylinder head cover gasket.

  23. REMOVE SPARK PLUG TUBE GASKET


    1. B00732N

      Using a screwdriver, deform each spark plug tube gasket inwards and remove the 6 spark plug tube gaskets from the cylinder head cover sub-assembly and cylinder head cover sub-assembly LH.

  24. REMOVE OIL PAN DRAIN PLUG


    1. Remove the oil pan drain plug and gasket from the No. 2 oil pan sub-assembly.

  25. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. B0077HVC05
      B0073AQ Bolt
      B0077IM Nut

      Remove the 15 bolts and 2 nuts.

    2. B0075W8

      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 pans.

  26. REMOVE ENGINE OIL LEVEL SENSOR

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  27. REMOVE OIL LEVEL SENSOR BRACKET

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  28. REMOVE OIL PAN SUB-ASSEMBLY


    1. B0074HNC02
      B0073AQ Bolt
      B0077IM Nut

      Remove the 16 bolts and 2 nuts.

      Note

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

    2. B0074G5C04
      *a LH Side
      *b RH Side

      Remove the oil pan sub-assembly by prying between the oil pan sub-assembly and timing chain cover assembly or cylinder block sub-assembly with a screwdriver wrapped with protective tape.

      Note

      Be careful not to damage the contact surfaces of the cylinder block sub-assembly, timing chain cover assembly and oil pan sub-assembly.

    3. B0075N8

      Remove the 2 O-rings from the timing chain cover assembly.

  29. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. B007521

      Remove the 3 nuts and oil strainer sub-assembly and gasket.

  30. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. B0072W2

      Remove the 8 bolts and No. 1 oil pan baffle plate.

  31. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. B00762R

      Remove the 6 bolts.

    2. B0073E1C02
      B0073AQ Pry

      Using a screwdriver with its tip wrapped with protective tape, pry out the engine rear oil seal retainer.

      Note

      Be careful not to damage the engine rear oil seal retainer.

  32. REMOVE ENGINE REAR OIL SEAL


    1. B0075C5C04
      *a Wooden Block
      *b Protective Tape

      Place the engine rear oil seal retainer on wooden blocks.

    2. Using a hammer and a screwdriver with its tip wrapped with protective tape, tap out the rear engine oil seal.

      Note

      Be careful not to damage the engine rear oil seal retainer.

  33. REMOVE TIMING CHAIN COVER PLATE

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  34. REMOVE TIMING CHAIN COVER ASSEMBLY

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  35. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. B0077PX

      Remove the 7 bolts and engine water pump assembly.

    2. Remove the water pump gasket.

  36. REMOVE TIMING CHAIN CASE OIL SEAL

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  37. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley set bolt.

    2. B0074UBC12
      *a Center Line
      *b Key Groove

      Turn the crankshaft clockwise to align the timing mark of the crankshaft timing sprocket key groove chase position with the center line of the block bore (for Bank 1) (TDC / compression).

    3. B0074TYC04
      *a Timing Mark

      Check that the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are aligned with the timing marks of the camshaft bearing caps as shown in the illustration.

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

      Note


      • Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear assembly and each camshaft timing exhaust gear assembly.

      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

  38. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B0072UKC26
      *a Plunger
      *b Stopper Plate
      *c Pin

      Turn the stopper plate clockwise to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.

    2. Turn the stopper plate counterclockwise to set the lock, and insert a 1.0 mm (0.0394 in.) diameter pin into the hole of the stopper plate.

    3. B0074JR

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

  39. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper from the cylinder block sub-assembly.

  40. REMOVE CHAIN SUB-ASSEMBLY


    1. B0072UDC03
      *a Mark
      *b Center Line
      *c 10°
      *d Key Groove

      Turn the crankshaft 10° counterclockwise to loosen the chain sub-assembly of the crankshaft timing gear or sprocket.

    2. Remove the crankshaft pulley set bolt from the crankshaft.

    3. B0072LO

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

    4. B0077AQC03
      *A for Bank 1

      Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) so that it is positioned as shown in the illustration.

      Note

      Be sure to loosen the chain sub-assembly between the banks.

    5. Remove the chain sub-assembly.

  41. REMOVE IDLE SPROCKET ASSEMBLY


    1. B0075HH

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

  42. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B0073J3

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

  43. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. B0075S6

      Remove the 2 No. 2 chain vibration dampers.

  44. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET


    1. B0077X2

      Remove the crankshaft timing gear or sprocket from the crankshaft.

    2. Remove the 2 crankshaft timing gear set keys from the crankshaft.

  45. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)

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  46. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

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  47. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

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  48. REMOVE FUEL PUMP LIFTER HOUSING

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  49. REMOVE CAMSHAFT

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  50. REMOVE NO. 2 CAMSHAFT

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  51. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

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  52. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)

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  53. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

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  54. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

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  55. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

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  56. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

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  57. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

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  58. REMOVE OIL CONTROL VALVE FILTER (for Bank 1)


    1. B0072R7

      Remove the 2 oil control valve filters from the 2 camshaft bearing caps.

  59. REMOVE OIL CONTROL VALVE FILTER (for Bank 2)


    1. Remove the 2 oil control valve filters from the camshaft bearing caps.

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

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  61. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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  62. REMOVE VALVE STEM CAP

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  63. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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  64. REMOVE CYLINDER HEAD GASKET

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  65. REMOVE CYLINDER HEAD LH

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  66. REMOVE NO. 2 CYLINDER HEAD GASKET

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  67. REMOVE NO. 5 ENGINE WIRE


    1. B00732W

      Disengage the 2 clamps, 2 connectors and remove the No. 5 engine wire.

  68. REMOVE KNOCK CONTROL SENSOR

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  69. REMOVE NO. 1 WATER OUTLET PIPE


    1. B007495

      Remove the 2 bolts and No. 1 water outlet pipe.

  70. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. B00762F

      Remove the 2 cylinder block water jacket spacers from the cylinder block sub-assembly.

  71. REMOVE STRAIGHT PIN

    Note

    It is not necessary to remove the straight pins unless they are being replaced.

  72. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

    Note

    It is not necessary to remove the camshaft bearing cap setting ring pins unless they are being replaced.