ENGINE UNIT DISASSEMBLY


  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. Remove the oil filler cap sub-assembly and oil filler cap gasket.

  2. REMOVE SPARK PLUG


    1. A01NLZO

      Remove the 6 spark plugs.

  3. REMOVE OIL PAN DRAIN PLUG


    1. A01NIEH

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

  4. REMOVE VENTILATION VALVE SUB-ASSEMBLY


    1. A01NLKS

      Remove the ventilation valve sub-assembly.

  5. REMOVE VVT SENSOR (for Bank 2)


    1. Disconnect the sensor connector.

    2. A01NK8Q

      Remove the bolt and sensor.

  6. REMOVE VVT SENSOR (for Bank 1)


    1. Disconnect the sensor connector.

    2. A01NJ8U

      Remove the bolt and sensor.

  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2)


    1. A01NKP1

      Disconnect the camshaft timing oil control valve assembly connector.

    2. Remove the bolt and camshaft timing oil control valve assembly.

    3. A01NMXPE01
      Text in Illustration
      *1 O-ring

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

  8. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1)


    1. A01NK8B

      Disconnect the camshaft timing oil control valve assembly connector.

    2. Remove the bolt and camshaft timing oil control valve assembly.

    3. A01NMXPE01
      Text in Illustration
      *1 O-ring

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

  9. REMOVE CRANK POSITION SENSOR


    1. A01NLKU

      Disconnect the crank position sensor connector.

    2. Remove the bolt and crank position sensor.

  10. REMOVE NO. 1 OIL PIPE


    1. A01NJXCE07
      Text in Illustration
      *a 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.

  11. REMOVE OIL PIPE


    1. A01NLAEE10
      Text in Illustration
      *a Oil Pipe Union
      *b Bolt

      Remove the bolt.

    2. Remove the 2 oil pipe unions, gaskets and oil pipe.

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

  12. REMOVE TAPER SCREW PLUG

    Tech Tips

    Perform this operation only when a taper screw plug is installed.


    1. A01NMZ1

      Remove the taper screw plug from the cylinder block sub-assembly.

  13. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. A01NK7CE04

      for Bank 1:


      1. Remove the cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.

      2. Remove the cylinder block water drain cock plug from the cylinder block water drain cock sub-assembly.

    2. for Bank 2:

      Tech Tips

      Perform this operation only when a cylinder block water drain cock sub-assembly is installed.


      1. Remove the cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.

      2. Remove the cylinder block water drain cock plug from the cylinder block water drain cock sub-assembly.

  14. REMOVE OIL FILTER ELEMENT


    1. A01NKID

      Remove the drain plug from the oil filter cap sub-assembly.

      Note

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

    2. A01NKLOE08
      Text in Illustration
      *a Pipe
      *b Hose
      *c O-ring

      Connect the hose to the pipe.

    3. Insert the pipe with the hose into the oil filter cap sub-assembly.

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

    5. A01NN0PE01

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

      SST
      09228-06501
    6. A01NJAZE23
      Text in Illustration
      *1 Oil Filter Element
      *a 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.

  15. REMOVE CRANKSHAFT PULLEY


    1. A01NN4YE02
      Text in Illustration
      *1 Hold
      *2 Turn

      Using SST, loosen the crankshaft pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A01NKBQE03
      Text in Illustration
      *1 Hold
      *2 Turn

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

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

  16. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01NJ1W

      Remove the bolt and engine oil level dipstick guide.

    2. A01NN7Z

      Remove the O-ring.

  17. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. A01NI7U

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

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

  18. REMOVE INLET WATER HOUSING


    1. A01NKT1

      Remove the 2 nuts, inlet water and thermostat.

    2. Remove the gasket.

    3. Remove the 2 stud bolts.

    4. Separate the No. 1 water by-pass hose from the inlet water housing.

    5. A01NNCAE02
      Text in Illustration
      *a Bolt
      *b Nut

      Remove the drain cock plug from the drain cock assembly.

    6. Remove the drain cock assembly from the inlet water housing.

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

    8. A01NIWI

      Remove the 2 O-rings.

  19. REMOVE OUTLET WATER


    1. A01NJ0EE02
      Text in Illustration
      *A w/ EGR System
      *B w/o EGR System
      *a Nut
      *b Bolt

      Remove the 2 bolts, 4 nuts and outlet water.

    2. A01NL0H

      Remove the 2 gaskets and O-ring.

  20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01NKHV

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

    2. A01NKU9

      Remove the 3 gaskets.

  21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01NJ5XE04
      Text in Illustration
      *a 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. A01NJET

      Remove the 3 gaskets.

  22. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01NINKE03
      Text in Illustration
      *a Nut

      Remove the 16 bolts and 2 nuts.

    2. A01NMU8

      Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and No. 2 oil pan sub-assembly. 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 pan sub-assembly and No. 2 oil pan sub-assembly.

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

  23. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01NK8VE04
      Text in Illustration
      *a Bolt
      *b Nut

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

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

  24. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01NIIFE05
      Text in Illustration
      *a 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. A01NLC7E04
      Text in Illustration
      *a 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 sub-assembly and oil pan sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A01NKDV

      Remove the 2 O-rings.

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

  25. REMOVE NO. 1 OIL PAN BAFFLE PLATE


    1. A01NMRD

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

  26. REMOVE REAR ENGINE OIL SEAL RETAINER


    1. A01NJJH

      Remove the 6 bolts.

    2. A01NLSCE03
      Text in Illustration
      *a Protective Tape
      A01NI58 Pry

      Using a screwdriver, pry out the rear engine oil seal retainer.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  27. REMOVE REAR ENGINE OIL SEAL


    1. A01NIONE11
      Text in Illustration
      *a Wooden Block
      *b Protective Tape

      Place the rear engine oil seal retainer on wooden blocks.

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  28. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01NLLV

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

  29. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01NJ2HE02
      Text in Illustration
      *a Nut

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

    2. A01NL0YE04
      Text in Illustration
      *a Protective Tape

      Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly 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 sub-assembly, cylinder block sub-assembly and timing chain cover sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    3. Remove the 4 bolts, chain cover plate and chain cover plate gasket.

    4. A01NL64

      Remove the gasket.

  30. REMOVE TIMING CHAIN CASE OIL SEAL


    1. A01NN9YE14
      Text in Illustration
      *a Protective Tape
      *b Wooden Block

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

      Tech Tips

      Tape the screwdriver tip before use.

  31. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily tighten the pulley set bolt.

    2. A01NN2QE11
      Text in Illustration
      *a Center Line
      *b Timing Mark
      *c 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. 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.

      A01NK0SE04
      Text in Illustration
      *a Timing Mark - -

      Tech Tips

      For the intake camshaft:

      Be sure to check mark A at the point where marks B, C, and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

      A01NMLGE01

      If not, turn the crankshaft clockwise 1 revolution (360°) and align the timing marks as above.

  32. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01NNAEE08
      Text in Illustration
      *a Plunger
      *b Stopper Plate
      *c Hexagon Wrench

      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 hexagon wrench into the hole of the stopper plate.

    3. A01NKOO

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

  33. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  34. REMOVE CHAIN SUB-ASSEMBLY


    1. A01NK85E01

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

    2. Remove the pulley set bolt.

    3. A01NK9J

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

    4. A01NJXPE01

      Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks.

    5. Remove the chain sub-assembly.

  35. REMOVE IDLE SPROCKET ASSEMBLY


    1. A01NIIS

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

  36. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01NI89

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

  37. REMOVE NO. 2 CHAIN VIBRATION DAMPER


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

  38. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A01NN3B

      Remove the crankshaft timing sprocket from the crankshaft.

    2. Remove the 2 keys from the crankshaft.

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


    1. A01NL7IE02
      Text in Illustration
      *1 Plunger
      *2 Pin

      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. A01NMVGE01
      Text in Illustration
      *1 Hold
      *2 Turn

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

      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.

  40. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01NKM2

      Remove the bolt and No. 2 chain tensioner assembly.

  41. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A01NMDKE02
      Text in Illustration
      *1 Knock Pin
      *2 Camshaft

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

    2. A01NLN4E01

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

    3. A01NKXOE01

      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.

      Tech Tips

      Arrange the removed parts in the correct order.

    4. Remove the 5 camshaft bearing caps.

  42. REMOVE CAMSHAFT


    1. Remove the camshaft.

  43. REMOVE NO. 2 CAMSHAFT


    1. Remove the No. 2 camshaft.

  44. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01NJKYE02
      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.

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


    1. A01NJ9KE03
      Text in Illustration
      *1 Plunger
      *2 Pin

      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. A01NJ18E03
      Text in Illustration
      *1 Hold
      *2 Turn

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

      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.

  46. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01NK7I

      Remove the bolt and No. 3 chain tensioner assembly.

  47. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A01NLKVE02
      Text in Illustration
      *1 Knock Pin
      *2 Camshaft

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

    2. A01NKZME01

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

    3. A01NKE7E01

      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.

      Tech Tips

      Arrange the removed parts in the correct order.

    4. Remove the 5 camshaft bearing caps.

  48. REMOVE NO. 3 CAMSHAFT


    1. Remove the No. 3 camshaft sub-assembly.

  49. REMOVE NO. 4 CAMSHAFT


    1. Remove the No. 4 camshaft sub-assembly.

  50. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01NNBJE02
      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.

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


    1. A01NJZOE01
      Text in Illustration
      *A Type A
      *B Type B
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

      Remove the 24 No. 1 valve rocker arms sub-assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  52. 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.

  53. REMOVE VALVE STEM CAP


    1. Remove the 24 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  54. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH


    1. A01NM8DE01

      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.

  55. REMOVE CYLINDER HEAD GASKET RH


    1. Remove the cylinder head gasket.

  56. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. A01NLUOE01

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

    2. A01NINWE01

      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 LH.

  57. REMOVE CYLINDER HEAD GASKET LH


    1. Remove the No. 2 cylinder head gasket.

  58. REMOVE INLET WATER PIPE


    1. Slide the clip and separate the No. 1 water by-pass hose.

    2. A01NK4VE01
      Text in Illustration
      *A w/ EGR System
      *B w/o EGR System

      Remove the 2 bolts and inlet water pipe.