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. A019OBP

      Remove the 6 spark plugs.

  3. REMOVE OIL PAN DRAIN PLUG


    1. A019KAW

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

  4. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A019L7N

      Remove the ventilation valve sub-assembly.

  5. REMOVE VVT SENSOR


    1. Disconnect the 4 sensor connectors.

    2. A019O9ME01

      Remove the 4 bolts and 4 sensors.

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A019OAR

      Remove the bolt and disconnect the wire harness clamp to separate the engine wire.

    2. Disconnect the 4 oil control valve connectors.

    3. A019KU2E02

      Remove the 4 bolts and 4 oil control valves.

    4. A019KC6E07
      Text in Illustration
      *1 O-ring

      Remove the O-ring from each oil control valve.

  7. REMOVE CRANK POSITION SENSOR


    1. A019L97

      Disconnect the crank position sensor connector.

    2. Remove the bolt and crank position sensor.

  8. REMOVE NO. 1 OIL PIPE


    1. A019JMNE02
      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. A019O2ME04
      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


    1. A019NY3E05

      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 ELEMENT


    1. A019KWP

      Remove the drain plug.

      Note

      Do not remove the O-ring from the oil filter cap.

    2. A019JQ9E05
      Text in Illustration
      *1 Pipe
      *2 Hose
      *3 O-ring

      Connect the hose to the pipe.

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

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

    5. A019O98E01

      Using SST, remove the oil filter cap sub-assembly.

      SST
      09228-06501
    6. A019KBGE12
      Text in Illustration
      *1 Oil Filter Element
      *2 O-ring

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

      Note

      Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.

  12. REMOVE CRANKSHAFT PULLEY


    1. A019NN9E01

      Using SST, loosen the crankshaft pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A019OEAE02

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

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
    3. A019KY0

      Remove the pulley set key from the crankshaft.

  13. REMOVE OIL COOLER ASSEMBLY


    1. A019KN7E01
      Text in Illustration
      *1 Clip
      *2 Clamp
      *3 Bolt

      Remove the bolt, 2 clamps and 4 clips, and disconnect the 2 water by-pass hoses.

    2. A019KI8

      Remove the union bolt, oil cooler assembly, and O-ring.

  14. REMOVE NO. 1 OIL COOLER BRACKET


    1. A019K3V

      Remove the 3 bolts, 3 nuts, and oil cooler pipe with the No. 1 oil cooler bracket.

    2. A019P83E02
      Text in Illustration
      *1 Nut
      *2 Bolt

      Remove the bolt, 2 nuts, No. 1 oil cooler bracket, and gasket.

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

  15. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A019MTB

      Remove the engine oil level dipstick guide.

    2. A019LNN

      Remove the O-ring.

  16. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A019OOU

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

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

  17. REMOVE WATER INLET HOUSING


    1. A019KNL

      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. A019NN5E02
      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. A019JNW

      Remove the 2 O-rings.

  18. REMOVE WATER OUTLET


    1. A019KAME02
      Text in Illustration
      *1 Nut
      *2 Bolt

      Remove the 2 bolts, 4 nuts and water outlet.

    2. A019O0X

      Remove the 2 gaskets and O-ring.

  19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A019N8Q

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

    2. A019N77

      Remove the 3 gaskets.

  20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A019MR5E05
      Text in Illustration
      *1 Baffle Plate

      Remove the 12 bolts, seal washer, cylinder head cover sub-assembly LH and 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. A019KNZ

      Remove the 3 gaskets.

  21. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A019MZHE02
      Text in Illustration
      *1 Nut

      Remove the 16 bolts and 2 nuts.

    2. A019LR8

      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.

  22. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A019MXTE03
      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.

  23. REMOVE OIL PAN SUB-ASSEMBLY


    1. A019M3AE01
      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. A019LORE02
      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. A019L7R

      Remove the 2 O-rings.

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

  24. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A019KO2

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

  25. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A019OV2

      Remove the 6 bolts.

    2. A019JWBE01

      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.

  26. REMOVE ENGINE REAR OIL SEAL


    1. A019JZRE05
      Text in Illustration
      *1 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.

  27. REMOVE WATER PUMP ASSEMBLY


    1. A019NS9

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

  28. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A019OFZE02
      Text in Illustration
      *1 Nut

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

    2. A019NKQE03
      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, chain cover plate and chain cover plate gasket.

    4. A019KJQ

      Remove the gasket.

  29. REMOVE TIMING CHAIN CASE OIL SEAL


    1. A019NN4E02
      Text in Illustration
      *1 Protective Tape
      *1 Wooden Block

      Using a screwdriver, pry out the timing chain case oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  30. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily tighten the pulley set bolt.

    2. A019NZBE01
      Text in Illustration
      *1 Center Line
      *2 Timing Mark
      *3 Sensor Plate

      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. A019NY8E05
      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 clockwise 1 revolution (360°) and align the timing marks as above.

  31. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A019OD0E03
      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. A019OCS

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

  32. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  33. REMOVE CHAIN SUB-ASSEMBLY


    1. A019OCOE01

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

    2. Remove the pulley set bolt.

    3. A019LNR

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

    4. A019P7PE08

      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.

  34. REMOVE IDLE SPROCKET ASSEMBLY


    1. A019KAF

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

  35. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A019OM1

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

  36. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. Remove the 2 No. 2 chain vibration dampers.

  37. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A019OAV

      Remove the crankshaft timing sprocket from the crankshaft.

    2. Remove the 2 keys from the crankshaft.

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


    1. A019O55E01

      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. A019JXNE02

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

      SST
      09922-10010

      Note

      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.

  39. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A019NIV

      Remove the bolt and No. 2 chain tensioner assembly.

  40. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A019OPHE01

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

    2. A019PC0E03

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

    3. A019LSXE01

      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.

  41. REMOVE CAMSHAFT


    1. Remove the camshaft.

  42. REMOVE NO. 2 CAMSHAFT


    1. Remove the No. 2 camshaft.

  43. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A019NF1E02
      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.

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


    1. A019LHIE01

      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. A019OU8E02

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

      SST
      09922-10010

      Note

      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.

  45. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A019NSF

      Remove the bolt and No. 3 chain tensioner assembly.

  46. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A019L42E01

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

    2. A019JLWE03

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

    3. A019P4ZE01

      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.

  47. REMOVE NO. 3 CAMSHAFT


    1. Remove the No. 3 camshaft.

  48. REMOVE NO. 4 CAMSHAFT


    1. Remove the No. 4 camshaft.

  49. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A019N4IE02
      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.

  50. 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.

  51. 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.

  52. REMOVE VALVE STEM CAP


    1. Remove the 24 valve stem caps.

  53. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH


    1. A019LPYE01

      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 an incorrect order.

      Tech Tips

      Arrange the removed parts in the correct order.

    2. Remove the cylinder head sub-assembly RH.

  54. REMOVE CYLINDER HEAD GASKET RH


    1. Remove the cylinder head gasket RH.

  55. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. A019LQRE01

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

    2. A019O57E01

      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 an incorrect order.

      Tech Tips

      Be sure to keep separate the removed parts for each installation position.

    3. Remove the cylinder head sub-assembly LH.

  56. REMOVE CYLINDER HEAD GASKET LH


    1. Remove the cylinder head gasket LH.

  57. REMOVE WATER INLET PIPE


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

    2. A019L3X

      Remove the 2 bolts and water inlet pipe.