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
1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

2. REMOVE OIL FILLER CAP HOUSING
(a) Remove the 2 bolts, filler cap housing and gasket.

3. REMOVE SPARK PLUG

4. REMOVE VVT SENSOR
(a) for Bank 1:
Remove the 2 bolts and 2 VVT sensors.

(b) for Bank 2: Remove the 2 bolts and 2 VVT sensors.

5. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and camshaft position sensor.

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

7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) for Bank 1:
Remove the bolt and oil control valve.

(b) for Bank 2: Remove the bolt and oil control valve.

8. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Remove the 2 water drain cock plugs from the water drain cocks.
(b) Remove the 2 water drain cocks from the cylinder block.

9. REMOVE CAMSHAFT TIMING CONTROL MOTOR (for Bank 1)
10. REMOVE CAMSHAFT TIMING CONTROL MOTOR (for Bank 2)
11. REMOVE OIL FILTER ELEMENT
12. REMOVE OIL FILTER BRACKET

13. REMOVE FRONT WATER BY-PASS JOINT
(a) Remove the 4 nuts, water by-pass joint and 2 gaskets.

14. REMOVE SPARK PLUG TUBE GASKET
(a) Using a screwdriver, pry out the 8 plug tube gaskets.

HINT: Tape the screwdriver tip before use.

15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
(a) Remove the fuel pump spacer gasket.
(b) Remove the 15 bolts, 2 seal washers, cylinder head cover and gasket.

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

16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
(a) Remove the fuel pump spacer gasket.
(b) Remove the 15 bolts, 2 seal washers, cylinder head cover and gasket.

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

17. REMOVE OIL CONTROL VALVE FILTER
(a) for Bank 1:
(1) Remove the 2 bolts, cylinder head cover spacer, gasket and valve filter.

(b) for Bank 2:
(1) Remove the 2 bolts, cylinder head cover spacer, gasket and valve filter.

18. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
19. REMOVE CRANKSHAFT PULLEY
20. REMOVE WATER PUMP
21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
22. REMOVE WATER INLET PIPE
23. SET NO. 1 CYLINDER TO TDC/COMPRESSION
24. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1)
25. REMOVE CHAIN TENSIONER SLIPPER (for Bank 1)
26. REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 1)
27. REMOVE CHAIN SUB-ASSEMBLY (for Bank 1)
28. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
29. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2)
30. REMOVE CHAIN TENSIONER SLIPPER (for Bank 2)
31. REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 2)
32. REMOVE CHAIN SUB-ASSEMBLY (for Bank 2)
33. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

34. REMOVE CRANKSHAFT TIMING GEAR KEY
(a) Using a screwdriver, remove the 2 timing gear keys from the crankshaft.

35. REMOVE CAMSHAFT BEARING CAP (for Bank 1)
36. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 1)
37. REMOVE CAMSHAFT BEARING CAP (for Bank 2)
38. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 2)
39. REMOVE NO. 1 VALVE ROCKER ARM SUBASSEMBLY
(a) Remove the 32 valve rocker arms from the cylinder head.

HINT: Arrange the removed parts in the correct order.

40. REMOVE VALVE LASH ADJUSTER ASSEMBLY
(a) Remove the 32 valve lash adjusters from the cylinder head.

HINT: Arrange the removed parts in the correct order.

41. REMOVE VALVE STEM CAP
(a) Remove the 32 valve stem caps from the cylinder head.

HINT: Arrange the removed parts in the correct order.

42. REMOVE CYLINDER HEAD SUB-ASSEMBLY (for Bank 1)
43. REMOVE CYLINDER HEAD SUB-ASSEMBLY (for Bank 2)

44. REMOVE CYLINDER BLOCK WATER JACKET SPACER
(a) 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.

45. REMOVE OIL RETURN PIPE GASKET
(a) Using a screwdriver, pry out the oil return pipe gasket.

HINT: Tape the screwdriver tip before use.

46. REMOVE NO. 1 HEAT EXCHANGER COVER
(a) Remove the 11 bolts and 2 nuts.

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

HINT: Tape the screwdriver tip before use.

47. REMOVE VENTILATION PIPE GASKET
(a) Using a screwdriver, pry out the ventilation pipe gasket.

HINT: Tape the screwdriver tip before use.

48. REMOVE OIL PAN PROTECTOR
(a) Remove the 2 nuts and oil pan protector.

49. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
(a) Remove the 15 bolts and 2 nuts.

(b) Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.
SST 09032-00100

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

50. REMOVE OIL PAN SUB-ASSEMBLY
(a) Remove the 14 bolts and 2 nuts.

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

(b) 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.

51. REMOVE OIL PAN BAFFLE PLATE
(a) Remove the 8 bolts and baffle plate.

52. REMOVE OIL STRAINER SUB-ASSEMBLY
(a) Remove the 2 bolts, oil strainer and O-ring.

53. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.

(b) Using a screwdriver, pry out the oil seal retainer.

HINT: Tape the screwdriver tip before use.

54. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY
(a) Remove the bolt and oil drain pipe.
(b) Remove the O-ring.

55. REMOVE NO. 1 VENTILATION CONNECTOR
(a) Remove the ventilation connector.

HINT: When removing the ventilation connector, the ventilation tube may come off the ventilation connector. If this occurs, do not forget to remove it from the cylinder block.

If the ventilation tube comes off, check for deformation and damage. If normal, attach the ventilation tube to the ventilation connector. If deformed or damaged, replace the ventilation connector assembly.