ENGINE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE OIL FILLER CAP


    1. Remove the oil filler cap.

  2. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A004JMME04

      Using SST, remove the oil filter sub-assembly.

      SST
      09228-22020

  3. REMOVE OIL FILTER UNION


    1. A004KQZ

      Remove the oil filter union.

  4. REMOVE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR


    1. A004KXY

      Using a 19 mm union nut wrench, remove the E.F.I. engine coolant temperature sensor.

  5. REMOVE KNOCK CONTROL SENSOR


    1. A004H31

      Remove the 2 bolts and 2 knock control sensors.

  6. REMOVE CRANK POSITION SENSOR


    1. A004JEN

      Remove the bolt and crank position sensor.

  7. REMOVE VVT SENSOR


    1. A004IYS

      Remove the bolt and VVT sensor (for intake side of bank 1).

    2. Remove the O-ring from the VVT sensor.

    3. A004JTQ

      Remove the bolt and VVT sensor (for exhaust side of bank 1).

    4. Remove the O-ring from the VVT sensor.

    5. A004HCI

      Remove the bolt and VVT sensor (for intake side of bank 2).

    6. Remove the O-ring from the VVT sensor.

    7. A004JZT

      Remove the bolt and VVT sensor (for exhaust side of bank 2).

    8. Remove the O-ring from the VVT sensor.

  8. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE


    1. A004ITD

      Remove the 2 bolts and camshaft timing oil control valve (for intake side of bank 1).

    2. A004HVEE05

      Remove the O-ring from the camshaft timing oil control valve.

    3. Remove the back-up ring from the camshaft timing oil control valve.

      Text in Illustration
      *1 O-ring
      *2 Back-up Ring
    4. A004IPV

      Remove the 2 bolts and camshaft timing oil control valve (for exhaust side of bank 1).

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

    6. Remove the back-up ring from the camshaft timing oil control valve.

    7. A004JGM

      Remove the 2 bolts and camshaft timing oil control valve (for intake side of bank 2).

    8. Remove the O-ring from the camshaft timing oil control valve.

    9. Remove the back-up ring from the camshaft timing oil control valve.

    10. A004K04

      Remove the 2 bolts and camshaft timing oil control valve (for exhaust side of bank 2).

    11. Remove the O-ring from the camshaft timing oil control valve.

    12. Remove the back-up ring from the camshaft timing oil control valve.

  9. REMOVE ENGINE OIL TEMPERATURE SENSOR


    1. A004H5RE01
      Text in Illustration
      *1 19 mm Deep Socket Wrench

      Using a 19 mm deep socket wrench, remove the engine oil temperature sensor.

      Note

      Use a cloth or the like to prevent engine oil from splashing.

  10. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A004HAKE01
      Text in Illustration
      *1 24 mm deep socket wrench

      Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.

      Note

      Use a cloth or the like to prevent engine oil from splashing.

  11. REMOVE PCV HOSE CONNECTOR


    1. A004H0J

      Remove the 3 bolts and PCV hose connector.

    2. Loosen the 2 clips and remove the No. 2 water by-pass hose from the PCV hose connector.

  12. REMOVE VACUUM PUMP ASSEMBLY (for Automatic Transmission)

    Click here

  13. REMOVE REAR CYLINDER HEAD PLATE (for Manual Transmission)


    1. A004KR7

      Remove the 3 bolts and rear cylinder head plate.

  14. REMOVE WATER INLET PIPE


    1. A004J4E

      Disconnect the No. 3 water by-pass hose.

    2. Remove the 4 bolts and water inlet pipe.

    3. A004HVW

      Remove the 2 O-rings from the cylinder block.

  15. REMOVE PCV VALVE SUB-ASSEMBLY


    1. A004KFN

      Using a 19 mm deep socket wrench, remove the PCV valve sub-assembly.

  16. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A004J6W

      Remove the bolt, No. 1 idler pulley sub-assembly and idler pulley cover.

  17. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A004I09

      Remove the bolt, No. 1 idler pulley sub-assembly and idler pulley cover.

  18. REMOVE WATER PUMP PULLEY


    1. A004ITHE03

      Using SST, hold the water pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    2. Remove the 3 bolts and water pump pulley.

  19. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A004H8A

      Remove the 5 bolts, engine water pump assembly and gasket.

  20. REMOVE WATER OUTLET


    1. A004ICJ

      Remove the 2 bolts and water outlet.

  21. REMOVE THERMOSTAT


    1. Remove the thermostat.

    2. Remove the gasket from the thermostat.

  22. REMOVE CRANKSHAFT PULLEY


    1. A004JJME03
      Text in Illustration
      *1 Claw

      Install SST to the crankshaft pulley.

      SST
      09213-80010   ( 90179-10016, 09213-08010, 09213-08110 )

      Tech Tips

      Position the projections on SST in the direction as shown in the illustration to prevent SST from separating from the crankshaft pulley.

    2. A004I8KE03
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, hold the crankshaft pulley and loosen the crankshaft pulley set bolt.

      SST
      09213-80010   ( 90179-10016, 09213-08010, 09213-08110 )

    3. Remove the crankshaft pulley.

    4. A004JAP

      Remove the O-ring and crankshaft pulley spacer.

  23. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL


    1. A004IPWE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, pry out the timing chain or belt cover oil seal.

      Note

      After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper.

      Tech Tips

      Tape the screwdriver tip before use.

  24. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY


    1. Remove the 32 bolts.

      A004IH6

    2. Using a screwdriver with its tip wrapped in protective tape, remove the timing chain or belt cover sub-assembly by prying between the timing chain or belt cover sub-assembly and cylinder head or cylinder block.

      A004IZIE01
      Text in Illustration
      *1 Protective Tape - -

      Note

      Be careful not to damage the contact surfaces of the cylinder head, cylinder block or chain cover.

    3. Remove the 4 O-rings.

      A004HKO

  25. MAKE PAINT MARKS

    Tech Tips

    If the alignment marks are difficult to identify during the work, mark the alignment marks with paint at the positions shown in the illustration, for easier recognition.

    A004IDVE01
    Text in Illustration
    *a Triangular Mark *b Engraved Line
    *c Oval Mark *d Crankshaft Timing Gear key

  26. REMOVE CHAIN SUB-ASSEMBLY (for Bank 1)

    CAUTION:

    Do not remove the chain sub-assembly from bank 2 at the same time as the chain sub-assembly is being removed from bank 1. Otherwise, the camshaft on bank 2 may turn suddenly, which is dangerous.


    1. A004HP7

      Temporarily install the crankshaft pulley spacer and crankshaft pulley.

    2. A004HR7E03
      Text in Illustration
      *a Alignment Mark
      *b Crankshaft Pulley Pin Hole
      *c Crankshaft Timing Gear key

      Using SST, turn the crankshaft pulley clockwise until the alignment marks on the camshaft timing intake gear assembly RH and the camshaft timing exhaust gear assembly RH, and the crankshaft pulley pin hole are aligned at the positions shown in the illustration.

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

      Tech Tips

      At this time, the alignment mark on the crankshaft timing gear or sprocket and the crankshaft timing gear key are at the positions shown in the illustration.

    3. Remove the crankshaft pulley and crankshaft pulley spacer.

    4. A004JUC

      Push down the chain tensioner slipper and retain the plunger by inserting a 2.5 mm (0.098 in.) diameter hexagonal wrench into the No. 1 chain tensioner assembly through the stopper plate.

    5. A004HNR

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

    6. Remove the chain tensioner slipper.

    7. A004JE1

      Using a 5 mm hexagonal wrench, remove the bolt and No. 1 chain vibration damper.

    8. Remove the chain sub- assembly (for bank 1).

      Note


      • With the chain sub- assembly (for bank 1) removed, the valve heads may contact each other if the camshafts are turned, causing the valve stems to bend.

      • To avoid this, do not turn the intake camshaft RH and the exhaust camshaft RH more than zero-lift range (The range where camshafts can be turned lightly by hand).

      Tech Tips

      Arrange the removed parts in the correct order.

  27. REMOVE CHAIN SUB-ASSEMBLY (for Bank 2)


    1. Temporarily install the crankshaft pulley spacer and crankshaft pulley.

    2. Using SST, turn the crankshaft pulley clockwise until the alignment marks on the camshaft timing intake gear assembly LH and the camshaft timing exhaust gear assembly LH, and the crankshaft pulley pin hole are aligned at the positions shown in the illustration.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      A004H5TE03
      Text in Illustration
      *a Alignment Mark *b Crankshaft Pulley Pin Hole
      *c Crankshaft Timing Gear key *d Cylinder Block Guide Pin

      Tech Tips

      At this time, the crankshaft timing gear key is at the position shown in the illustration.

    3. Remove the crankshaft pulley and crankshaft pulley spacer.

    4. A004JX9

      Push the chain tensioner slipper and retain the plunger by inserting an approximately 1 mm (0.039 in.) diameter wire into the No. 2 chain tensioner assembly through the stopper plate .

    5. A004H2S

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

    6. Remove the chain tensioner slipper.

    7. A004INR

      Remove the O-ring from the cylinder block.

    8. A004KBU

      Using a 5 mm socket hexagon wrench, remove the bolt and No. 1 chain vibration damper.

    9. A004JW4E01

      While releasing the tension of chain sub-assembly using SST, remove the chain sub-assembly.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

      CAUTION:

      Make sure to use SST. Never carry out the work using only your hands.

      Note


      • With the chain sub-assembly (for bank 2) removed, the valve heads may contact each other if the camshafts are turned, causing the valve stems to bend. To avoid this, do not turn the exhaust camshaft LH more than zero-lift rang (The range where the camshaft can be turned lightly by hand).

      • At this time, No. 1 and No. 4 pistons are located near TDC. If the intake camshaft is turned, the valves may come into contact with the piston, causing the valve stems to bend. To avoid this, do not turn the intake camshaft LH.

      Tech Tips

      Arrange the removed parts in the correct order.

  28. ROTATE CRANK SHAFT AND CAMSHAFT

    Click here

  29. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET


    1. A004ITW

      Remove the crankshaft timing gear or sprocket.

  30. REMOVE CAMSHAFT TIMING INTAKE GEAR ASSEMBLY RH

    Click here

  31. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY RH

    Click here

  32. REMOVE CAMSHAFT TIMING INTAKE GEAR ASSEMBLY LH

    Click here

  33. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY LH

    Click here

  34. REMOVE SPARK PLUG


    1. Using a 14 mm spark plug wrench, remove the 4 spark plugs.

  35. REMOVE INJECTOR DRIVER BRACKET


    1. A004JBM

      Remove the 2 bolts and injector driver bracket.

  36. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. Operate the engine stand so that the bank 1 side faces upward.

    2. A004JV7

      Remove the 8 bolts.

    3. Using a screwdriver with its tip wrapped in protective tape, remove the cylinder head cover sub-assembly RH.

      Note

      Do not damage the camshaft housing sub-assembly RH, cam caps and cylinder head cover sub-assembly RH.

    4. Remove the cylinder head cover gasket.

    5. A004KKV

      Remove the 2 spark plug tube gaskets.

      Note

      When removing the seal packing left on the camshaft housing sub-assembly RH using a scraper, use special care not to damage the camshafts.

  37. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

    Note

    Do not remove the intake and exhaust camshafts first as it may cause a deformation of the cylinder head sub-assembly.


    1. A004JYAE03

      Loosen the 9 bolts in the order shown in the illustration and remove them.

    2. Using a screwdriver with its tip wrapped in protective tape, remove the camshaft housing sub-assembly RH.

      Note

      Do not damage the cylinder head sub-assembly RH and camshaft housing sub-assembly RH.

    3. A004HYC

      Remove the 2 O-rings and 8 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

    4. A004KM5

      Remove the 8 valve adjusting shims and 8 roller rocker arm pivots from the cylinder head sub-assembly.

      Tech Tips


      • Arrange the removed parts in the correct order.

      • When installing, be sure to install the removed parts in their original locations.

  38. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

    Click here

  39. REMOVE CYLINDER HEAD GASKET

    Click here

  40. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. Operate the engine stand so that the bank 2 side faces upward.

    2. A004IW8

      Remove the 8 bolts.

    3. Using a screwdriver with its tip wrapped in protective tape, remove the cylinder head cover sub-assembly LH.

      Note

      Do not damage the camshaft housing sub-assembly LH, cam caps and cylinder head cover sub-assembly LH.

    4. Remove the cylinder head cover gasket.

    5. A004ILR

      Remove the 2 spark plug tube gaskets.

      Note

      When removing the seal packing left on the camshaft housing sub-assembly LH using a scraper, use special care not to damage the camshafts.

  41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

    Note

    Do not remove the intake and exhaust camshafts first as it may cause a deformation of the camshaft housing sub-assembly LH.


    1. A004ICRE03

      Loosen the 9 bolts in the order shown in the illustration and remove them.

    2. Using a screwdriver with its tip wrapped in protective tape, remove the camshaft housing sub-assembly LH.

      Note

      Do not damage the cylinder head sub-assembly LH and camshaft housing sub-assembly LH.

    3. A004KF2

      Remove the 2 O-rings and 8 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly LH.

      Tech Tips

      Arrange the removed parts in the correct order.

    4. A004K5L

      Remove the 8 valve adjusting shims and 8 roller rocker arm pivots from the cylinder head sub-assembly LH.

      Tech Tips


      • Arrange the removed parts in the correct order.

      • When installing, be sure to install the removed parts in their original locations.

  42. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

    Click here

  43. REMOVE NO. 2 CYLINDER HEAD GASKET

    Click here

  44. REMOVE NO. 2 ENGINE HANGER

    A004J78

    1. Remove the 2 bolts and No. 2 engine hanger from the cylinder block (for bank 1).

  45. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. Remove the drain plug and gasket.

    2. A004K4X

      Remove the 11 bolts.

    3. A004KL9

      Using an oil pan seal cutter, remove the No. 2 oil pan sub-assembly.

      Note

      Do not damage the contact surface and flange part of the No. 2 oil pan sub-assembly.

    4. A004J69

      Remove the 2 seal rings from the No. 2 oil pan sub-assembly.

  46. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A004HAV

      Remove the 2 bolts and oil strainer sub-assembly.

    2. Remove the O-ring.

  47. REMOVE OIL PAN SUB-ASSEMBLY


    1. A004IAYE01
      Text in Illustration
      *a Use a TORX Socket Wrench T45

      Remove the 13 bolts.

    2. Using a screwdriver with its tip wrapped in protective tape, remove the oil pan sub-assembly.

      Note

      Do not damage the cylinder block and oil pan sub-assembly.

    3. A004I7I

      Remove the 3 O-rings from the cylinder block.

    4. A004I8F

      Remove the 4 bolts and baffle plate from the oil pan sub-assembly.

    5. A004HCJ

      Remove the 2 stud bolts from the oil pan sub-assembly.

  48. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

    Click here

  49. REMOVE CAMSHAFT (for Bank 1)

    Click here

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


    1. A004KJX

      Remove the 2 oil control valve filters from the camshaft housing sub-assembly RH.

  51. REMOVE OIL SPACER RH


    1. A004IVD

      Remove the 2 bolts and oil spacer RH.

  52. REMOVE CAMSHAFT OIL FEED PIPE SUB-ASSEMBLY (for Automatic Transmission)


    1. A004KM9

      Remove the 2 union bolts, the bolt, camshaft oil feed pipe sub-assembly and 2 gaskets from the camshaft housing sub-assembly RH.

  53. REMOVE HOLE PLUG (for Manual Transmission)


    1. A004JBF

      Remove the hole plug and gasket from the camshaft housing sub-assembly RH.

  54. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

    Click here

  55. REMOVE CAMSHAFT (for Bank 2)

    Click here

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


    1. A004KI9

      Remove the 2 oil control valve filters from the camshaft housing sub-assembly LH.

  57. REMOVE OIL SPACER LH


    1. A004I3J

      Remove the 2 bolts and oil spacer LH.