ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap and gasket.

  2. REMOVE RADIATOR CAP SUB-ASSEMBLY

  3. REMOVE SPARK PLUG


    1. Remove the 6 spark plugs.

  4. REMOVE OIL PAN DRAIN PLUG


    1. Remove the drain plug and gasket.

  5. REMOVE PCV VALVE SUB-ASSEMBLY


    1. A01FGQD

      Disconnect the PCV valve hose.

    2. Remove the PCV valve.

  6. REMOVE VVT SENSOR (for Intake Side of Bank 1)


    1. A01FJ0Q

      Disconnect the VVT sensor connector.

    2. Remove the bolt and VVT sensor.

  7. REMOVE VVT SENSOR (for Exhaust Side of Bank 1)


    1. A01FHON

      Disconnect the VVT sensor connector.

    2. Remove the bolt and VVT sensor.

  8. REMOVE VVT SENSOR (for Intake Side of Bank 2)


    1. A01FHT5

      Disconnect the VVT sensor connector.

    2. Remove the bolt and VVT sensor.

  9. REMOVE VVT SENSOR (for Exhaust Side of Bank 2)


    1. A01FI0Q

      Disconnect the VVT sensor connector.

    2. Remove the bolt and VVT sensor.

  10. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1)

    A01FH4S

    1. Disconnect the oil control valve connector.

    2. Remove the bolt and oil control valve.

    3. Remove the O-ring from the oil control valve.

  11. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1)


    1. A01FEUN

      Remove the bolt and V-bank cover bracket.

    2. A01FFC7

      Disconnect the oil control valve connector.

    3. Remove the bolt and oil control valve.

    4. Remove the O-ring from the oil control valve.

  12. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2)


    1. A01FHRZ

      Disconnect the oil control valve connector.

    2. Remove the bolt and oil control valve.

    3. Remove the O-ring from the oil control valve.

  13. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2)


    1. A01FDRS

      Disconnect the 2 wiring harness clamps from the bracket.

    2. Remove the 2 bolts and bracket.

    3. A01FGGF

      Disconnect the oil control valve connector.

    4. Remove the bolt and oil control valve.

    5. Remove the O-ring from the oil control valve.

  14. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01FHOYE02

      Disconnect the crankshaft position sensor connector.

    2. Remove the bolt and crankshaft position sensor.

  15. REMOVE NO. 1 OIL PIPE


    1. A01FFOME06
      Text in Illustration
      *1 Oil Pipe Union
      *2 Oil Check Valve Bolt

      Remove the oil check valve bolt, oil pipe union and No. 1 oil pipe.

    2. Remove the oil control valve filter LH and gaskets.

  16. REMOVE NO. 2 OIL PIPE


    1. A01FGGSE05
      Text in Illustration
      *1 Oil Pipe Union
      *2 Oil Check Valve Bolt

      Remove the oil check valve bolt, oil pipe union and No. 2 oil pipe.

    2. Remove the oil control valve filter RH and gaskets.

  17. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A01FE4FE11
      Text in Illustration
      *a RH Side
      *b LH Side

      Remove the water drain cocks from the cylinder block.

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

  18. REMOVE OIL FILTER ELEMENT


    1. A01FIYAE02
      Text in Illustration
      *1 Rib

      Using SST, remove the oil filter cap.

      SST
      09228-06501

      Tech Tips

      Use a container to catch the draining oil. After the oil filter cap is loosened approximately 4 turns and the cap ribs are vertical, engine oil drains from the gap between the oil filter cap and oil pan.

    2. A01FGIEE01
      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.

  19. REMOVE CRANKSHAFT PULLEY


    1. A01FGZLE05
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, loosen the pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A01FI58E09
      Text in Illustration
      *a Hold
      *b Turn

      Tighten the pulley bolt to 2 or 3 threads of the crankshaft.

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

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

      Tech Tips

      Apply grease to the threads and tip of SST (center bolt) prior to use.

  20. REMOVE WATER INLET SUB-ASSEMBLY


    1. A01FE8Y

      Separate the 3 water by-pass hoses.

    2. A01FF2Z

      Remove the 4 bolts, nut and water inlet.

    3. A01FE9O

      Remove the 2 O-rings.

    4. A01FEUZ

      Remove the 3 water by-pass hoses.

  21. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY


    1. A01FGOA

      Remove the 3 nuts and water inlet with thermostat.

    2. Remove the gasket from the water inlet.

  22. REMOVE REAR WATER BY-PASS JOINT


    1. A01FERC

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

    2. A01FE8A

      Remove the 2 gaskets and O-ring.

  23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01FGJ5

      Remove the 14 bolts, head cover sub-assembly and gasket.

    2. A01FHPL

      Remove the 3 gaskets.

  24. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01FIOGE06
      Text in Illustration
      *1 Baffle Plate

      Remove the 12 bolts, head cover sub-assembly LH and 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 head cover.

    2. A01FDN3

      Remove the 3 gaskets.

  25. REMOVE SPARK PLUG TUBE GASKET


    1. A01FIE6E06
      Text in Illustration
      *1 Claw

      Pry up the claws of the ventilation baffle plate.

      Note

      Do not deform the claws of the baffle plate more than necessary.

    2. A01FILC

      Using a screwdriver as shown in the illustration, deform each spark plug tube gasket inwards and remove the 6 spark plug tube gaskets from the the cylinder head cover.

      Note


      • As much as possible prevent the plug tube gaskets from being deformed. The removed gaskets will be used when reinstalling the gaskets.

      • Do not damage the connection of the cylinder head cover.

      • Make sure not to damage the spark plug tube gasket and cylinder head cover when inserting the screwdriver in the joint area.

      Tech Tips

      If the cylinder head cover is damaged, smooth the surface with 400-grit sandpaper.

  26. REMOVE OIL PAN DRAIN PLUG


    1. Remove the oil pan drain plug and gasket.

  27. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01FIXU

      for 2WD:

      Remove the 15 bolts and 2 nuts.

      Text in Illustration
      A01FGIV Bolt
      A01FJ4N Nut
    2. A01FHU1

      Insert the blade of 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.

  28. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01FHHF

      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. A01FFE1E10
      Text in Illustration
      *a LH Side
      *b RH Side

      Remove the oil pan by prying between the oil pan and cylinder block 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. A01FGPSE02

      Remove the 2 O-rings.

  29. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01FEVL

      Remove the 3 nuts, oil strainer and gasket.

    2. A01FGKW

      Remove the 8 bolts and baffle plate.

  30. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01FIRK

      Remove the 6 bolts.

    2. A01FHG2

      Using a screwdriver, pry out the oil seal retainer.

      Text in Illustration
      A01FGIV Pry

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  31. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A01FIEDE06
      Text in Illustration
      *1 Wooden Block
      *2 Protective Tape

      Place the oil seal retainer on wooden blocks.

      Note

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

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

      Tech Tips

      Tape the screwdriver tip before use.

  32. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01FG0F

      Remove the bolt and wire harness clamp bracket.

    2. A01FDTV

      Remove the 25 bolts and 2 nuts shown in the illustration.

    3. A01FG7GE07

      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.

    4. A01FHAUE03

      Remove the gasket.

  33. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01FGA9

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

  34. REMOVE TIMING CHAIN CASE OIL SEAL


    1. A01FINUE03
      Text in Illustration
      *1 Wooden Block

      Using a screwdriver, pry out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  35. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily tighten the pulley set bolt.

    2. A01FGWVE02
      Text in Illustration
      *1 Timing Mark
      *a Center Line

      Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC/compression).

    3. A01FIO7E01
      Text in Illustration
      *1 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 1 revolution (360°) and align the timing marks as above.

  36. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01FDIGE04
      Text in Illustration
      *1 Stopper Plate
      *2 Plunger

      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 (0.0500 in.) diameter into the hole of the stopper plate.

    3. Install the chain tensioner with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Remove the lock pin of the chain tensioner.

  37. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  38. REMOVE CHAIN SUB-ASSEMBLY


    1. A01FFWSE04
      Text in Illustration
      *1 Timing Mark
      *a Center Line

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

    2. Remove the pulley set bolt.

    3. A01FEOP

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

    4. A01FEXEE17
      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 between the banks.

    5. Remove the chain.

  39. REMOVE IDLE SPROCKET ASSEMBLY


    1. A01FI0EE01

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

  40. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01FDTC

      Remove the 2 bolts and vibration damper.

  41. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A01FGKP

      Remove the 2 vibration dampers.

  42. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01FDLM

      Remove the crankshaft timing sprocket from the crankshaft.

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

  43. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)


    1. A01FI6WE11
      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. A01FI2CE08
      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 RH.

      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.

  44. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01FDUO

      Remove the bolt and No. 2 chain tensioner assembly.

  45. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A01FDDNE01
      Text in Illustration
      *1 Knock Pin
      *a IN
      *b EX

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

    2. A01FFE5E01

      Uniformly loosen and remove the 9 bearing cap bolts in several steps and in the sequence shown in the illustration.

    3. A01FD91E01

      Uniformly loosen and remove the 14 bearing cap bolts in several steps and in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

  46. REMOVE CAMSHAFT

  47. REMOVE NO. 2 CAMSHAFT

  48. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01FGD9E02
      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.

  49. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)


    1. A01FEIKE09
      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. A01FGE8E06
      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 LH.

      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.

  50. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01FI5T

      Remove the bolt and No. 3 chain tensioner assembly.

  51. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A01FFWRE01
      Text in Illustration
      *1 Knock Pin
      *a IN
      *b EX

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

    2. A01FDCME01

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

    3. A01FJ2UE01

      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.

  52. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

  53. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

  54. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01FHMWE02
      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.

  55. REMOVE VALVE STEM CAP


    1. Remove the 24 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

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


    1. Remove the 24 No. 1 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  57. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 24 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  58. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01FIH6E01

      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.

      • 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.

    2. Remove the cylinder head sub-assembly.

  59. REMOVE CYLINDER HEAD GASKET

  60. REMOVE CYLINDER HEAD LH


    1. A01FH3ZE02

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

    2. A01FESFE02

      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.

      • 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.

  61. REMOVE NO. 2 CYLINDER HEAD GASKET

  62. REMOVE NO. 5 ENGINE WIRE


    1. A01FHMN

      Detach the clamp and remove the No. 5 engine wire.

  63. REMOVE KNOCK CONTROL SENSOR


    1. A01FE4PE01

      Disconnect the 2 knock sensor connectors.

      Text in Illustration
      A01FJ4N Front

    2. Remove the 2 bolts and 2 knock sensors.

  64. REMOVE CYLINDER BLOCK WATER JACKET SPACER RH


    1. A01FIFNE01

      Using needle-nose pliers, remove the cylinder block water jacket spacer RH.

      Note

      Be sure to remove the water jacket spacer if turning the cylinder block.

  65. REMOVE CYLINDER BLOCK WATER JACKET SPACER LH


    1. Using needle-nose pliers, remove the cylinder block water jacket spacer LH.

      Note

      Be sure to remove the water jacket spacer if turning the cylinder block.

  66. REMOVE WATER OUTLET PIPE SUB-ASSEMBLY


    1. A01FIJM

      Remove the 2 bolts and water outlet pipe.

  67. REMOVE NO. 1 STRAIGHT PIN

    Note

    It is not necessary to remove a No. 1 straight pin unless it is being replaced.

  68. REMOVE RING PIN

    Note

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