Disassembly

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

DISASSEMBLY

HINT:
^ Thoroughly clean all parts to be assembled.
^ Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
^ Replace all gaskets, O-rings and oil seals with new ones.

1. REMOVE OIL PRESSURE SWITCH
(a) Using a 24 mm deep socket wrench, remove the oil pressure switch.

2. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a) Remove the engine coolant temperature sensor and gasket.

3. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Remove the 2 water drain cocks.

4. REMOVE VVT SENSOR
(a) Remove the 2 bolts and 2 VVT sensors from the cylinder head LH and RH.

5. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the bolt and crankshaft position sensor.

6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Remove the 2 bolts and 2 camshaft timing oil control valves from the cylinder head LH and RH.
(b) Remove the 2 O-rings.

7. REMOVE OIL CONTROL VALVE FILTER
(a) Remove the 2 unions, 2 filters and 2 gaskets from cylinder head LH and RH.
8. REMOVE OIL FILTER SUB-ASSEMBLY

9. DISCONNECT NO. 2 OIL COOLER HOSE
10. DISCONNECT OIL COOLER HOSE

11. REMOVE OIL COOLER ASSEMBLY
(a) Remove the oil cooler union bolt, plate washer and oil cooler.

12. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY
(a) Remove the 3 bolts, 2 nuts, oil filter bracket and O-ring.
13. DISCONNECT NO. 1 WATER BY-PASS HOSE
14. DISCONNECT NO. 2 WATER BY-PASS HOSE
15. DISCONNECT NO. 3 WATER BY-PASS HOSE

16. REMOVE WATER INLET HOUSING
(a) Remove the 5 bolts and water inlet housing.
(b) Remove the O-ring and gasket from the water outlet pipe and water pump.

17. REMOVE REAR WATER BY-PASS JOINT
(a) Remove the 2 bolts, 4 nuts, rear water by-pass joint and 2 gaskets.
(b) Remove the O-ring from the No. 1 water outlet pipe.

18. REMOVE OIL FILLER CAP SUB-ASSEMBLY
19. REMOVE OIL FILLER CAP HOUSING
(a) Remove the 2 nuts, oil filler cap housing and gasket.
20. REMOVE SPARK PLUG
(a) Remove the 6 spark plugs.

21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH
(a) Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket.
22. REMOVE VENTILATION VALVE SUB-ASSEMBLY
(a) Remove the ventilation valve.

23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket.

24. REMOVE CRANKSHAFT PULLEY
(a) Turn the crankshaft pulley, and align the notch with the timing mark "0" of the timing chain cover.

(b) Check that the timing marks of the camshaft timing gears and sprockets are aligned with the timing marks of the bearing caps as shown in the illustration.

(d) Using the pulley set bolt and SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05030)
25. REMOVE OIL PAN DRAIN PLUG
(a) Remove the drain plug and gasket.
26. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
27. REMOVE OIL STRAINER SUB-ASSEMBLY
28. REMOVE OIL PAN SUB-ASSEMBLY

29. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 5 bolts and 2 nuts.
(b) Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and crankshaft bearing cap.

30. REMOVE REAR CRANKSHAFT OIL SEAL
(a) Using a screwdriver and hammer, tap out the oil seal.

NOTICE: Be careful not to damage the rear oil seal retainer.

31. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
(a) Remove the 24 bolts labeled A and B, and 2 nuts.

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

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

(c) Remove the O-ring from the cylinder head LH side.

32. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 8 bolts, water pump and gasket.
33. REMOVE FRONT CRANKSHAFT OIL SEAL
34. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

NOTICE:
^ Never rotate the crankshaft with the chain tensioner removed.
^ When rotating the camshaft with the timing chain removed, rotate the crankshaftcounterclockwise 40° from the TDC first.

(a) While turning the stopper plate of the tensioner clockwise, push in the plunger of the chain tensioner as shown in the illustration.
(b) While turning the stopper plate of the tensioner counterclockwise, insert a bar of [diameter]3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate.
(c) Remove the 2 bolts and chain tensioner.
35. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the chain tensioner slipper.

36. REMOVE NO. 1 IDLE GEAR SHAFT
(a) Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, No. 1 idle gear and No. 1 idle gear shaft.

37. REMOVE NO. 2 CHAIN VIBRATION DAMPER
(a) Remove the 2 No. 2 chain vibration dampers.
38. REMOVE NO. 1 CHAIN
(a) Remove the No. 1 chain.

39. REMOVE CRANKSHAFT TIMING SPROCKET
(a) Remove the crankshaft timing sprocket.

40. REMOVE NO. 1 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts and No. 1 chain vibration damper.

41. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)
(a) While raising the No. 2 chain tensioner, insert a pin of [diameter]1.0 mm (0.0394 in.) into the hole to fix it.

(b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing sprocket and No. 2 chain.

NOTICE:
^ Be careful not to damage the cylinder head and valve lifter with the wrench.
^ Do not disassemble the camshaft timing gear.

42. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Remove the bolt and No. 2 chain tensioner.

43. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)
(a) While raising the No. 3 chain tensioner, insert a pin of [diameter]1.0 mm (0.0394 in.) into the hole to fix it.

44. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Remove the bolt and No. 3 chain tensioner.
45. REMOVE NO. 1 CAMSHAFT AND NO. 2 CAMSHAFT (for Bank 1)

NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

(a) Remove the No. 1 and No. 2 camshafts.
(1) Rotate the camshafts counterclockwise using a wrench so that the cam lobes of the No. 1 cylinder face each direction as shown in the illustration.

(2) Uniformly loosen and remove the 16 bearing cap bolts in the sequence shown in the illustration.
(3) Remove the 8 bearing caps and 2 camshafts.

46. REMOVE NO. 1 CAMSHAFT BEARING (for Bank 1)

47. REMOVE NO. 2 CAMSHAFT BEARING (for Bank 1)

48. REMOVE NO. 3 CAMSHAFT AND NO. 4 CAMSHAFT (for Bank 2)
(a) Remove the No. 3 and No. 4 camshafts.
(1) Uniformly loosen and remove the 16 bearing cap bolts in the sequence shown in the illustration.
(2) Remove the 8 bearing caps and 2 camshafts.

49. REMOVE CYLINDER HEADS
(a) Using a 10 mm bi-hexagon wrench, uniformly loosen the 2 bolts in the sequence shown in the illustration. Remove the 2 cylinder head bolts and plate washers.

(b) Using a 10 mm bi-hexagon wrench, uniformly loosen the 16 bolts in the sequence shown in the illustration. Remove the 16 cylinder head bolts and plate washers.

NOTICE:
^ Be careful not to drop the plate washers into the cylinder head.
^ Cylinder head warpage or cracking could result from removing bolts in the incorrect order.

(c) Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver.

50. REMOVE CYLINDER HEAD GASKET
51. REMOVE NO. 2 CYLINDER HEAD GASKET

52. REMOVE NO. 1 WATER OUTLET PIPE
(a) Remove the 3 bolts and water outlet pipe.

53. REMOVE KNOCK SENSOR
(a) Remove the 2 bolts and 2 knock sensors.