Engine Unit Disassembly

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.

Disconnect the oil pressure sender gauge connector.

Remove the oil pressure sender gauge.

Remove the 2 bolts, 2 nuts and filter bracket.

Remove the 2 O-rings.

Using SST, remove the crankshaft pulley set bolt.

SST

09213-70011
09330-00021

Text in Illustration

*a	Hold
	Turn

Temporarily install the pulley set bolt to the crankshaft until 2 or 3 threads are engaged.

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 oil filler cap.

Remove the gasket from the oil filler cap.

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

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

Disconnect the 4 knock sensor connectors.

Remove the 4 bolts and 4 knock sensors.

Disconnect the 4 VVT sensor connectors.

Remove the 4 bolts and 4 VVT sensors.

Disconnect the camshaft position sensor connector.

Remove the bolt and camshaft position sensor.

Remove the 2 bolts and crankshaft position sensor protector.

Disconnect the crankshaft position sensor connector.

Remove the bolt and crankshaft position sensor.

for Bank 1:
Remove the 2 bolts and 2 camshaft oil control valves.

for Bank 2:
Remove the 2 bolts and 2 camshaft oil control valves.

Remove the 2 water drain cock plugs from the cylinder block water drain cocks.

Remove the 2 cylinder block water drain cocks from the cylinder block.

Remove the 3 bolts and water inlet housing.

Remove the gasket from the engine water pump.

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

Remove the 14 bolts, seal washer, cylinder head cover sub-assembly LH and cylinder head cover gasket LH.

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).

Text in Illustration

Gasket

Remove the 14 bolts, seal washer, cylinder head cover sub-assembly RH and cylinder head cover gasket RH.

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).

Text in Illustration

Gasket

for Bank 1:
Remove the 3 bolts, cylinder head cover spacer, gasket and oil control valve filter.

for Bank 2:
Remove the 3 bolts, cylinder head cover spacer, gasket and oil control valve 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.

NOTICE:

Be careful not to damage the cylinder head cover.

HINT:

1. Be careful not to damage the gasket when removing it as the removed gasket needs to be used when installing a new one.
   
2. Tape the screwdriver tip before use.
   

Disconnect the oil level sensor connector.

Remove the 4 bolts and oil level sensor.

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

HINT:

Remove the only the outer part of the gasket.

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

Remove the 26 bolts and nut shown in the illustration.

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

Text in Illustration

Protective Tape

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Remove the gasket from the cylinder block.

Remove the O-ring from the oil pan.

Remove the 8 bolts, engine water pump and gasket.

Remove the water inlet pipe.

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

Place the timing chain cover on wooden blocks.

Place the oil pump on a wooden block.

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

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Temporarily install the pulley set bolt.

Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear 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 upward to release the lock and push the plunger deep into the No. 1 chain tensioner.

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

Remove the 2 bolts, No. 1 chain tensioner LH and gasket.

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

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

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

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 No. 3 chain tensioner.

Move the stopper plate upward to release the lock and push the plunger deep into the No. 1 chain tensioner.

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

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

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

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

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

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 No. 2 chain tensioner.

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

Make sure that the knock pins of the camshafts are 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 camshaft bearing caps.

HINT:

Arrange the removed parts in the correct order.

Remove the No. 3 camshaft from the camshaft housing LH.

Remove the No. 4 camshaft from the camshaft housing LH.

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 pins of the camshafts are 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 camshaft bearing caps.

HINT:

Arrange the removed parts in the correct order.

Remove the No. 1 camshaft from the camshaft housing RH.

Remove the No. 2 camshaft from the camshaft housing RH.

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 No. 1 valve rocker arms from the cylinder head.

HINT:

Arrange the removed parts in the correct order.

Remove the 32 valve lash adjusters from the cylinder head.

HINT:

Arrange the removed parts in the correct order.

Remove the 32 valve stem caps from the cylinder head.

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 LH.

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.

Remove the 2 cylinder block water jacket spacers from the cylinder block.

NOTICE:

Be sure to remove the cylinder block water jacket spacers. Otherwise, they may fall and become damaged when the cylinder block is inverted.

Using a screwdriver, pry out the oil return pipe gasket.

HINT:

Tape the screwdriver tip before use.

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 No. 1 heat exchanger cover by prying between the No. 1 heat exchanger cover 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 No. 1 oil pan by prying between the No. 1 oil pan and cylinder block with a screwdriver.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder block and No. 1 oil pan.

HINT:

Tape the screwdriver tip before use.

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

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

Remove the 6 bolts and rear engine oil seal retainer.

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

HINT:

Tape the screwdriver tip before use.

Place the rear engine oil seal retainer on wooden blocks.

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

Remove the bolt and oil drain pipe.

Remove the O-ring.