Engine Unit Disassembly

Disconnect the sender gauge connector.

Remove the oil pressure sender gauge.

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.

NOTICE:

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

HINT:

Use a container to catch the draining oil.

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 cap O-ring by hand, without using any tools, to prevent damage to the cap O-ring groove.

Remove the 2 nuts and bracket.

Disconnect the ground wire from the cylinder block.

Remove the 2 bolts, 2 nuts and filter bracket.

Remove the 2 O-rings.

Remove the 2 bolts, filler cap housing and gasket.

Using a 16 mm plug wrench, remove the 8 spark plugs.

LH:
Remove the 2 bolts and 2 VVT sensors.

RH:
Remove the 2 bolts and 2 VVT sensors.

Remove the bolt and camshaft position sensor.

Remove the 2 bolts and sensor protector.

Remove the bolt and crankshaft position sensor.

Disconnect the oil level sensor connector.

Remove the 4 bolts and oil level sensor.

Remove the gasket from the oil level sensor.

HINT:

After cutting away the parts of the gasket shown in the illustration, remove only the outer part of the gasket.

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

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

Using SST, hold the water pump pulley.

SST

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

Remove the 4 bolts and water pump pulley.

Remove the bolt and idler pulley.

Remove the 4 bolts and fluid coupling bracket.

Remove the standard bolt, 6 mm hexagon wrench bolt and belt tensioner.

Remove the 14 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 5 gaskets from the camshaft bearing caps (No. 2, No. 3).

Remove the bolt and noise filter.

Remove the 14 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 5 gaskets from the camshaft bearing caps (No. 1, No. 3).

LH:
Remove the 3 bolts, cylinder head cover spacer, gasket and filter.

RH:
Remove the 3 bolts, cylinder head cover spacer, gasket and filter.

Bend the 4 ventilation baffle plate claws on the cylinder head cover to an angle of 90° or more.

Using a screwdriver, pry out the gaskets.

Text in Illustration

*1	Tape
	Pry

NOTICE:

1. Be careful not to damage the cylinder head cover.
   
2. Be careful not to damage the gasket when removing it, as the removed gasket needs to be used when installing a new one.
   

HINT:

Tape the screwdriver tip before use.

Using SST, loosen the crankshaft pulley set bolt until 2 or 3 threads are engaged.

SST

09213-70011
09330-00021

Text in Illustration

*a	Hold
	Turn

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

SST

09950-50013(09951-05010,09952-05010,09953-05010,09954-05011)

Text in Illustration

*a	Hold
	Turn

Remove the 8 bolts, water pump and gasket.

Remove the 28 bolts and nut shown in the illustration.

Text in Illustration

	Bolt
	Nut

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

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Remove the oil pump gasket from the cylinder block.

Remove the O-ring from the oil pan.

Remove the water inlet pipe.

Remove the 2 O-rings from the water inlet pipe.

Place the timing chain cover on wooden blocks.

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

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Temporarily install the crankshaft pulley bolt.

Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.

HINT:

If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

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

Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

Remove the 2 bolts, chain tensioner and gasket.

Remove the 2 bolts and chain vibration damper.

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

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

Text in Illustration

*a	Hold
	Turn

NOTICE:

1. Be careful not to damage the cylinder head with the wrench.
   
2. Do not disassemble the camshaft timing gear.
   

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

Text in Illustration

*a	Hold
	Turn

NOTICE:

Be careful not to damage the cylinder head with the wrench.

Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket LH.

Remove the No. 1 and No. 2 chains from the gears.

Remove the 2 bolts and chain tensioner.

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

Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

Remove the 2 bolts and chain tensioner.

Remove the 2 bolts and vibration damper.

While raising up the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

Text in Illustration

*a	Hold
	Turn

NOTICE:

1. Be careful not to damage the cylinder head with the wrench.
   
2. Do not disassemble the camshaft timing gear.
   

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

Text in Illustration

*a	Hold
	Turn

NOTICE:

Be careful not to damage the cylinder head with the wrench.

Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket RH.

Remove the No. 1 and No. 2 chains from the gears.

Remove the 2 bolts and chain tensioner.

Using a screwdriver, remove the 2 timing gear keys from the crankshaft.

Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

NOTICE:

Uniformly loosen the bolts while keeping the camshaft level.

Remove the 6 bearing caps.

HINT:

Arrange the removed parts in the correct order.

Remove the No. 3 and No. 4 camshafts.

HINT:

Arrange the removed parts in the correct order.

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

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

NOTICE:

Uniformly loosen the bolts while keeping the camshaft level.

Remove the 6 bearing caps.

HINT:

Arrange the removed parts in the correct order.

Remove the No. 1 and No. 2 camshafts.

HINT:

Arrange the removed parts in the correct order.

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

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Remove the 32 valve rocker arms from the cylinder heads.

HINT:

Arrange the removed parts in the correct order.

Remove the 32 valve lash adjusters from the cylinder heads.

HINT:

Arrange the removed parts in the correct order.

Remove the 32 valve stem caps from the cylinder heads.

HINT:

Arrange the removed parts in the correct order.

Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

NOTICE:

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

HINT:

Be sure to arrange the removed parts for each installation position separately.

Remove the cylinder head and gasket.

Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

NOTICE:

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

HINT:

Be sure to arrange the removed parts for each installation position separately.

Remove the cylinder head and gasket.

Remove the 2 water jacket spacers from the cylinder block.

NOTICE:

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

Using a screwdriver, pry out the ventilation pipe gasket.

HINT:

Tape the screwdriver tip before use.

Remove the 12 bolts and 2 nuts.

Text in Illustration

	Bolt
	Nut

Remove the heat exchanger by prying between the heat exchanger and cylinder block with a screwdriver.

HINT:

Tape the screwdriver tip before use.

Remove the 14 bolts and 2 nuts.

Text in Illustration

	Bolt
	Nut

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 14 bolts and 2 nuts.

Text in Illustration

	Bolt
	Nut

HINT:

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

Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Remove the 7 bolts and baffle plate.

Remove the 2 bolts, oil strainer and O-ring.

Remove the 6 bolts and oil seal retainer.

Using a screwdriver, pry out the oil seal retainer.

HINT:

Tape the screwdriver tip before use.

Remove the bolt and oil drain pipe.

Remove the O-ring.

Place the oil seal retainer on wooden blocks.

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