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. A01FVY3

      Disconnect the PCV valve hose.

    2. Using a 22 mm socket wrench, remove the PCV valve from the No. 2 separator case.

  6. DISCONNECT NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01FVTM

      Remove the bolt and disconnect the No. 2 water by-pass pipe.

  7. REMOVE WATER BY-PASS HOSE ASSEMBLY

  8. REMOVE NO. 2 SEPARATOR CASE


    1. A01FT2V

      Remove the 2 nuts, No. 2 separator case and O-ring.

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


    1. A01FVLW

      Disconnect the VVT sensor connector.

    2. Remove the bolt and VVT sensor.

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


    1. A01FS5X

      Disconnect the VVT sensor connector.

    2. Remove the bolt and VVT sensor.

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


    1. A01FVIJ

      Disconnect the VVT sensor connector.

    2. Remove the bolt and VVT sensor.

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


    1. A01FRTB

      Disconnect the VVT sensor connector.

    2. Remove the bolt and VVT sensor.

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

    A01FQMP

    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.

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


    1. A01FR8Q

      Disconnect the oil control valve connector.

    2. Remove the bolt and oil control valve.

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

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


    1. A01FSD7

      Disconnect the oil control valve connector.

    2. Remove the bolt and oil control valve.

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

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


    1. A01FSAZ

      Disconnect the oil control valve connector.

    2. Remove the bolt and oil control valve.

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

  17. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01FSRNE02

      Disconnect the crankshaft position sensor connector.

    2. Remove the bolt and crankshaft position sensor.

  18. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A01FQ7PE11
      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.

  19. REMOVE OIL FILTER ELEMENT


    1. A01FRGQE02
      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. A01FQPQE01
      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.

  20. REMOVE CRANKSHAFT PULLEY


    1. A01FR49E01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, loosen the pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A01FQ5UE01
      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.

  21. REMOVE WATER INLET SUB-ASSEMBLY


    1. A01FV32

      Separate the 3 water by-pass hoses.

    2. A01FS5K

      Remove the 4 bolts, nut and water inlet.

    3. A01FRNA

      Remove the 2 O-rings.

    4. A01FTNP

      Remove the 3 water by-pass hoses.

  22. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY


    1. A01FTRO

      Remove the 3 nuts and water inlet with thermostat.

    2. Remove the gasket from the water inlet.

  23. REMOVE REAR WATER BY-PASS JOINT


    1. A01FSQ9

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

    2. A01FU6V

      Remove the 2 gaskets and O-ring.

  24. REMOVE FUEL PUMP SPACER GASKET


    1. Remove the fuel pump spacer gasket from the cylinder head cover.

  25. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Detach the clamps and disconnect the connectors to disconnect the wire harness from the cylinder head cover.

    2. A01FT4B

      Remove the 15 bolts, cylinder head cover and gasket.

    3. A01FQ74

      Remove the 5 gaskets.

  26. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. Detach the clamps and disconnect the connectors to disconnect the wire harness from the cylinder head cover LH.

    2. A01FTKS

      Remove the 16 bolts, cylinder head cover LH and gasket.

    3. A01FVXX

      Remove the 5 gaskets.

  27. REMOVE SPARK PLUG TUBE GASKET


    1. A01FSAOE01
      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. A01FVFW

      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.

  28. REMOVE OIL PAN DRAIN PLUG


    1. Remove the oil pan drain plug and gasket.

  29. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01FS55

      Remove the 15 bolts and 2 nuts.

      Text in Illustration
      A01FTNO Bolt
      A01FRJI Nut
    2. A01FUAW

      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.

  30. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01FTLQ

      Remove the 16 bolts and 2 nuts.

      Text in Illustration
      A01FTNO Bolt
      A01FRJI Nut

      Tech Tips

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

    2. A01FR7IE10
      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. A01FTKZE02

      Remove the 2 O-rings.

  31. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01FUA6

      Remove the 3 nuts, oil strainer and gasket.

    2. A01FUOE

      Remove the 8 bolts and baffle plate.

  32. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01FSKC

      Remove the 6 bolts.

    2. A01FRQO

      Using a screwdriver, pry out the oil seal retainer.

      Text in Illustration
      A01FTNO Pry

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  33. REMOVE REAR CRANKSHAFT OIL SEAL


    1. A01FVYWE06
      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.

  34. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01FUHV

      Remove the bolt and wire harness clamp bracket.

    2. A01FSG4

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

    3. A01FVHJE09
      Text in Illustration
      *1 Protective Tape

      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. A01FSNXE03

      Remove the gasket.

  35. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01FSXA

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

  36. REMOVE TIMING CHAIN CASE OIL SEAL


    1. A01FV8QE07
      Text in Illustration
      *1 Wooden Block
      *2 Protective Tape

      Using a screwdriver, pry out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  37. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the pulley set bolt.

    2. A01FQ0UE04
      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. A01FVRDE01
      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 described above.

  38. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01FVDME07
      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 (0.0500 in.) diameter into the stopper plate's hole.

    3. A01FT5L

      Remove the 2 bolts and chain tensioner.

  39. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  40. REMOVE CHAIN SUB-ASSEMBLY


    1. A01FUM7E04
      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. A01FT2Z

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

    4. A01FQM7E17
      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.

  41. REMOVE IDLE SPROCKET ASSEMBLY


    1. A01FUQ6E01

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

  42. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01FSHN

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

  43. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A01FUSJ

      Remove the 2 No. 2 chain vibration dampers.

  44. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01FRIR

      Remove the crankshaft timing sprocket from the crankshaft.

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

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


    1. A01FRS6E01
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

      While raising the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 2 chain tensioner.

    2. A01FTWVE01
      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.

  46. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01FQ9O

      Remove the bolt and No. 2 chain tensioner.

  47. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A01FQ8DE01
      Text in Illustration
      *1 Knock Pin
      *a IN
      *b EX

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

    2. A01FSL8E01

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

    3. A01FTQKE01

      Uniformly loosen and remove the 15 bearing cap bolts in several steps and in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

  48. REMOVE FUEL PUMP LIFTER HOUSING


    1. A01FVPJ

      Remove the fuel pump lifter housing.

  49. REMOVE CAMSHAFT

  50. REMOVE NO. 2 CAMSHAFT

  51. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01FRD3E01
      Text in Illustration
      *1 Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. A01FUYUE01
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

      While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 3 chain tensioner.

    2. A01FVBDE01
      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.

  53. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01FUZ5

      Remove the bolt and No. 3 chain tensioner.

  54. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A01FVRGE01
      Text in Illustration
      *1 Knock Pin
      *a IN
      *b EX

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

    2. A01FV7WE01

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

    3. A01FVTWE01

      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.

  55. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

  56. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

  57. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01FU0TE01
      Text in Illustration
      *1 Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  58. REMOVE OIL CONTROL VALVE FILTER LH


    1. A01FTDM

      Remove the oil control valve filter LH from the camshaft bearing cap.

  59. REMOVE OIL CONTROL VALVE FILTER RH


    1. Remove the oil control valve filter RH from the camshaft bearing cap.

  60. REMOVE OIL CHECK VALVE


    1. A01FQU7

      Remove the oil check valve from the camshaft bearing cap.

  61. 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.

  62. 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.

  63. REMOVE VALVE STEM CAP


    1. Remove the 24 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  64. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01FRZNE01

      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.

  65. REMOVE CYLINDER HEAD GASKET

  66. REMOVE CYLINDER HEAD LH


    1. A01FSNQE01

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

    2. A01FQX9E01

      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 LH.

  67. REMOVE NO. 2 CYLINDER HEAD GASKET

  68. REMOVE NO. 5 ENGINE WIRE


    1. A01FTOL

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

  69. REMOVE KNOCK SENSOR


    1. A01FTUL

      Disconnect the 2 knock sensor connectors.

      Text in Illustration
      A01FRJI Front

    2. Remove the 2 bolts and 2 knock sensors.

  70. REMOVE WATER OUTLET PIPE SUB-ASSEMBLY


    1. A01FV2L

      Remove the 2 bolts and water outlet pipe.

  71. REMOVE NO. 1 STRAIGHT PIN

    Note

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

  72. REMOVE RING PIN

    Note

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