Engine Unit Disassembly

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

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

Remove the gasket from the sensor.

Remove the water drain cock plug from the water drain cock.

Remove the water drain cock from the cylinder block.

LH:
Remove the 2 bolts and 2 VVT sensors.

RH:
Remove the 2 bolts and 2 VVT sensors.

Remove the bolt and crankshaft position sensor.

LH:
Remove the 2 bolts and 2 oil control valves.

RH:
Remove the 2 bolts and 2 oil control valves.

Remove the oil filler cap.

Remove the 2 nuts, oil filler cap housing and gasket.

Remove the 2 oil pipe unions, oil control valve filter LH, 3 gaskets and No. 1 oil pipe.

NOTICE:

Do not touch the mesh when removing the oil control valve filter.

Remove the 2 oil pipe unions, oil control valve filter RH, 3 gaskets and No. 2 oil pipe.

NOTICE:

Do not touch the mesh when removing the oil control valve filter.

Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

Remove the oil filter drain plug.

Install the pipe to the oil filter cap.

HINT:

Use a container to catch the draining oil.

NOTICE:

If the O-ring is removed with the drain plug, install the O-ring together with the pipe.

Check that oil is drained from the oil filter. Then, disconnect the pipe and remove the O-ring as shown in the illustration.

Using SST, remove the oil filter cap.

SST

09228-06501

NOTICE:

Do not remove the oil filter bracket clip.

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

NOTICE:

Be sure to remove the O-ring (for the cap) by hand, without using any tools, to prevent damage to the groove for the O-ring in the cap.

Remove the 2 nuts, bolt, oil filter bracket and gasket.

Disconnect the 3 water by-pass hoses.

Remove the 5 bolts and water inlet housing.

Remove the O-ring and gasket from the water outlet pipe and water pump.

Remove the 3 water by-pass hoses.

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

Remove the O-ring from the No. 1 water outlet pipe.

Remove the 6 spark plugs.

Remove the PCV valve hose.

Remove the PCV valve.

Using SST, hold the crankshaft pulley and loosen the pulley bolt. Continue to loosen the bolt until only 2 or 3 threads are screwed into the crankshaft.

SST

09213-54015(91651-60855)
09330-00021

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

SST

09950-50013(09951-05010,09952-05010,09953-05020,09954-05031)

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

HINT:

Make sure the removed parts are returned to the same places they were removed from.

Remove the 3 gaskets.

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

HINT:

Make sure the removed parts are returned to the same places they were removed from.

Remove the 3 gaskets.

Bend the ventilation baffle plate claws on the cylinder head cover to an angle of 90° or more.

Text in Illustration

Pry

Remove the 6 spark plug tube gaskets.

HINT:

Be careful not to damage the gasket when removing it as the removed gasket needs to be used when installing a new one.

Disconnect the connector.

Remove the 4 bolts and sensor.

Cut away part of the gasket and remove the gasket from the engine oil level sensor.

HINT:

Remove only the outer part of the gasket.

Remove the drain plug and gasket.

Remove the 10 bolts and 2 nuts.

HINT:

Make sure the removed parts are returned to the same places they were removed from.

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.

NOTICE:

Be careful not to damage the contact surfaces of the oil pans.

Remove the 2 nuts, oil strainer and gasket.

Remove the 17 bolts and 2 nuts.

HINT:

Make sure the removed parts are returned to the same places they were removed from.

Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block as shown in the illustration.

HINT:

Tape the screwdriver tip before use.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder block and oil pan.

Remove the 3 O-rings from the timing chain cover.

Remove the 6 bolts and No. 1 oil pan baffle plate.

Remove the 5 bolts and 2 nuts.

Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and crankshaft bearing cap.

HINT:

Tape the screwdriver tip before use.

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

NOTICE:

Be careful not to damage the rear oil seal retainer.

Remove the 26 bolts and the 2 nuts.

Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.

HINT:

Tape the screwdriver tip before use.

NOTICE:

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

Remove the oil pump gasket from the cylinder block.

Remove the 8 bolts, water pump and gasket.

Using a screwdriver and wooden block, pry out the oil seal.

HINT:

Tape the screwdriver tip before use.

NOTICE:

Do not damage the surface of the oil seal press fit hole.

Temporarily install the pulley set bolt.

Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression).

Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration.
If not, turn the crankshaft clockwise 1 revolution (360°) and align the timing marks as above.

Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

Move the stopper plate downward to set the lock, and insert a pin of φ1.27 mm (0.0500 in.) into the stopper plate hole.

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

Remove the chain tensioner slipper.

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

Remove the pulley set bolt.

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

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

Remove the chain sub-assembly.

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

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

Remove the 2 No. 2 chain vibration dampers.

Remove the crankshaft timing sprocket.

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

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

SST

09922-10010

NOTICE:

Do not loosen the other 4 bolts. If any of the 4 bolts is loosened, replace the camshaft timing gear assembly and/or camshaft timing exhaust gear assembly with a new one.

Remove the 2 bolts and camshaft timing gear assembly together with the No. 2 chain.

Remove the bolt and No. 2 chain tensioner assembly.

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

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

Uniformly loosen and remove the 12 bearing cap bolts in several steps in the sequence shown in the illustration.

NOTICE:

Uniformly loosen the bolts while keeping the camshaft level.

Remove the 5 camshaft bearing caps.

Remove the camshaft and No. 2 camshaft.

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

HINT:

Tape the screwdriver tip before use.

NOTICE:

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

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

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

SST

09922-10010

NOTICE:

Do not loosen the other 4 bolts. If any of the 4 bolts is loosened, replace the camshaft timing gear assembly and/or camshaft timing exhaust gear assembly with a new one.

Remove the 2 bolts and camshaft timing gear together with the No. 2 chain.

Remove the bolt and No. 3 chain tensioner assembly.

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

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

Uniformly loosen and remove the 13 bearing cap bolts in several steps in the sequence shown in the illustration.

NOTICE:

Uniformly loosen the bolts while keeping the camshaft level.

Remove the 5 camshaft bearing caps.

Remove the No. 3 camshaft and No. 4 camshaft.

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

HINT:

Tape the screwdriver tip before use.

NOTICE:

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

Remove the 24 valve rocker arms from the cylinder head.

HINT:

Arrange the removed parts in the correct order.

Remove the 24 valve lash adjusters from the cylinder head.

HINT:

Arrange the removed parts in the correct order.

Remove the 24 valve stem caps from the cylinder head.

HINT:

Arrange the removed parts in the correct order.

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.

NOTICE:

1. Be careful not to drop washers into the cylinder head sub-assembly.
   
2. Cylinder head warpage or cracking could result from removing bolts in an incorrect order.
   

HINT:

Arrange the removed parts in the correct order.

Remove the cylinder head sub-assembly.

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

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.

NOTICE:

1. Be careful not to drop washers into the cylinder head sub-assembly.
   
2. Cylinder head warpage or cracking could result from removing bolts in an incorrect order.
   

HINT:

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

Remove the cylinder head LH.

Detach the 3 wire harness clamps.

Remove the 2 nuts, bolt and water outlet pipe.

Disconnect the 2 sensor connectors.

Remove the 2 bolts and 2 sensors.

Remove the 2 water jacket spacers from the cylinder head.

NOTICE:

Be sure to remove the water jacket spacers. If not, they may fall and become damaged when the cylinder block is inverted.