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. A01EW7C

      Remove the 6 spark plugs.

  3. REMOVE OIL PAN DRAIN PLUG


    1. A01EUP2

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

  4. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A01EUOW

      Remove the ventilation valve sub-assembly.

  5. REMOVE VVT SENSOR


    1. Disconnect the 4 sensor connectors.

    2. A01EWA8E02
      Text in Illustration
      *a for Bank 1
      *b for Bank 2
      *c for Intake Side
      *d for Exhaust Side

      Remove the 4 bolts and 4 sensors.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. Disconnect the 4 oil control valve connectors.

    2. A01EUBBE01
      Text in Illustration
      *a for Intake Side
      *b for Exhaust Side
      *c for Bank 2
      *d for Bank 1

      Remove the 4 bolts and 4 oil control valves.

    3. A01EX7ZE06
      Text in Illustration
      *1 O-ring

      Remove the O-ring from each oil control valve.

  7. REMOVE CRANK POSITION SENSOR


    1. A01ETIR

      Disconnect the crank position sensor connector.

    2. Remove the bolt and crank position sensor.

  8. REMOVE NO. 1 OIL PIPE


    1. A01EU0XE02
      Text in Illustration
      *1 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.

  9. REMOVE OIL PIPE


    1. A01EYHZE04
      Text in Illustration
      *1 Oil Pipe Union
      *2 Bolt

      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

    A01EV9XE07
    Text in Illustration
    *a for Bank 1
    *b for Bank 2

    1. 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 CAP ASSEMBLY


    1. A01EZ3AE01
      Text in Illustration
      *1 Pipe
      *2 Hose

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

    2. A01ETLI

      Remove the oil filter drain plug from the oil filter cap.

    3. A01EXV8E02
      Text in Illustration
      *1 Cap
      *2 O-ring
      *3 Pipe

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

      Note

      Be sure to insert the pipe with the O-ring installed on the oil filter cap.

      Tech Tips

      Place the hose end into a container before draining oil from the hose.

    4. A01EVJF

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

      Tech Tips

      Be sure to turn the pipe in the direction of the arrow to remove it.

    5. A01EUY3E01

      Using SST, remove the oil filter cap.

      SST
      09228-06501
    6. A01EYXVE06
      Text in Illustration
      *1 Oil Filter Element
      *2 Oil Filter Cap
      *3 O-ring

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

      Note

      Do not use any tools to remove the O-ring in order to prevent the cap from being damaged. Be sure to remove it by hand.

  12. REMOVE CRANKSHAFT PULLEY


    1. A01EUF9E03
      Text in Illustration
      *a Hold
      A01EUL1 Turn

      Using SST, loosen the crankshaft pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A01EVS4E01
      Text in Illustration
      *a Hold
      A01EUL1 Turn

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
    3. A01EXT1

      Remove the pulley set key from the crankshaft.

  13. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01EXOM

      Remove the bolt and engine oil level dipstick guide.

    2. A01ET5W

      Remove the O-ring.

  14. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A01ETS7

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

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

  15. REMOVE WATER INLET HOUSING


    1. A01EUAF

      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. A01EXR6E04
      Text in Illustration
      *1 Nut
      *2 Bolt

      Remove the drain cock plug.

    6. Remove the drain cock assembly.

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

    8. A01EU1W

      Remove the 2 O-rings.

  16. REMOVE WATER OUTLET


    1. A01EXXOE02
      Text in Illustration
      *1 Nut
      *2 Bolt

      Remove the 2 bolts, 4 nuts and water outlet.

    2. A01EXBW

      Remove the 2 gaskets and O-ring.

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01EW4Z

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

    2. A01ETMJ

      Remove the 3 gaskets.

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01ETBRE05
      Text in Illustration
      *1 Baffle Plate

      Remove the 12 bolts, seal washer, cylinder head cover sub-assembly LH and No. 2 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 LH.

    2. A01ETRB

      Remove the 3 gaskets.

  19. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01EYNDE02
      Text in Illustration
      *1 Nut

      Remove the 16 bolts and 2 nuts.

    2. A01EXBT

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

  20. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01EYVLE03
      Text in Illustration
      *1 Bolt
      *2 Nut

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

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

  21. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01EXQ7E03
      Text in Illustration
      *1 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. A01EY9QE02
      Text in Illustration
      *1 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 and oil pan.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A01EU3B

      Remove the 2 O-rings.

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

  22. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01EUVL

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

  23. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01ETMF

      Remove the 6 bolts.

    2. A01EYCTE02
      Text in Illustration
      *1 Protective Tape
      A01EUL1 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.

  24. REMOVE ENGINE REAR OIL SEAL


    1. A01ET9JE07
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

      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 ENGINE WATER PUMP ASSEMBLY


    1. A01EW8X

      Remove the 16 bolts, engine water pump assembly and water pump gasket.

  26. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01EULZE02
      Text in Illustration
      *1 Nut

      Remove the 15 bolts and 2 nuts as shown in the illustration.

    2. A01EVORE04
      Text in Illustration
      *1 Protective Tape

      Remove the timing chain cover sub-assembly by prying between the timing chain cover and cylinder head sub-assembly or cylinder block sub-assembly 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 4 bolts, timing chain cover plate and timing chain cover plate gasket.

    4. A01EUQG

      Remove the gasket.

  27. REMOVE TIMING CHAIN CASE OIL SEAL


    1. A01EUQ7E05
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

      Using a screwdriver and wooden block, pry out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  28. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily tighten the pulley set bolt.

    2. A01EY1ME02
      Text in Illustration
      *1 Sensor Plate
      *a Center Line
      *b Timing Mark

      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. A01EUNQE07
      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.

  29. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01EUW3E06
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate
      *3 Pin

      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 (0.0500 in.) into the stopper plate hole.

    3. A01EXZ8

      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. A01EVNUE02
      Text in Illustration
      *1 Sensor Plate
      *a Center Line
      *b Timing Mark

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

    2. Remove the pulley set bolt.

    3. A01EY2D

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

    4. A01EZ4DE13
      Text in Illustration
      *a for Bank 1

      Turn the camshaft timing gear assembly on 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. A01EU03

      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. A01EWWD

      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. A01EXKV

      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. A01EYS3E08
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

      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. A01EWZ8E06
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

      SST
      09922-10010

      Note


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

      • Do not loosen the other bolts. If any of the 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. A01EYQB

      Remove the bolt and No. 2 chain tensioner assembly.

  38. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A01ET6TE08
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A01ETPIE03

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

    3. A01ETZ4E01

      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. A01EW4PE02
      Text in Illustration
      *1 Protective Tape

      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. A01EXVHE07
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

      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. A01EYI5E06
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

      SST
      09922-10010

      Note


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

      • Do not loosen the other bolts. If any of the 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. A01ESV0

      Remove the bolt and No. 3 chain tensioner assembly.

  44. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A01EYBRE06
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A01EX8GE03

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

    3. A01EZ4KE01

      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. A01EYZOE02
      Text in Illustration
      *1 Protective Tape

      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. A01ESVYE01

      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 the 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. A01EXRPE01

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

    2. A01EUKME01

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

    2. A01EU5U

      Remove the 2 bolts and water inlet pipe.