Disassembly [06/2016 - ]: Procedure
- REMOVE OIL FILLER CAP ASSEMBLY
- Remove the oil filler cap assembly.
- REMOVE OIL FILTER SUB-ASSEMBLY
- REMOVE OIL FILTER UNION
- REMOVE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
- REMOVE KNOCK CONTROL SENSOR
- REMOVE CRANK POSITION SENSOR
- REMOVE VVT SENSOR
- Remove the bolt and VVT sensor (for intake side of bank 1).
- Remove the O-ring from the VVT sensor.
- Remove the bolt and VVT sensor (for exhaust side of bank 1).
- Remove the O-ring from the VVT sensor.
- Remove the bolt and VVT sensor (for intake side of bank 2).
- Remove the O-ring from the VVT sensor.
- Remove the bolt and VVT sensor (for exhaust side of bank 2).
- Remove the O-ring from the VVT sensor.
- Remove the bolt and VVT sensor (for intake side of bank 1).
- REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
- Remove the 2 bolts and camshaft timing oil control valve (for intake side of bank 1).
- Remove the O-ring from the camshaft timing oil control valve.
- Remove the back-up ring from the camshaft timing oil control valve.TEXT IN ILLUSTRATION
*1 O-ring *2 Back-up Ring - Remove the 2 bolts and camshaft timing oil control valve (for exhaust side of bank 1).
- Remove the O-ring from the camshaft timing oil control valve.
- Remove the back-up ring from the camshaft timing oil control valve.
- Remove the 2 bolts and camshaft timing oil control valve (for intake side of bank 2).
- Remove the O-ring from the camshaft timing oil control valve.
- Remove the back-up ring from the camshaft timing oil control valve.
- Remove the 2 bolts and camshaft timing oil control valve (for exhaust side of bank 2).
- Remove the O-ring from the camshaft timing oil control valve.
- Remove the back-up ring from the camshaft timing oil control valve.
- Remove the 2 bolts and camshaft timing oil control valve (for intake side of bank 1).
- REMOVE TEMPERATURE SENSOR
- REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
- REMOVE PCV HOSE CONNECTOR
- REMOVE VACUUM PUMP ASSEMBLY (for Automatic Transmission)
Refer to PROCEDURE - Step 3
- REMOVE REAR CYLINDER HEAD PLATE (for Manual Transmission)
- REMOVE WATER INLET PIPE
- REMOVE PCV VALVE SUB-ASSEMBLY
- REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY
- REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY
- REMOVE WATER PUMP PULLEY
- REMOVE ENGINE WATER PUMP ASSEMBLY
- REMOVE WATER OUTLET
- REMOVE THERMOSTAT
- Remove the thermostat.
- Remove the gasket from the thermostat.NOTE:
Be careful not to let SST slip during the work.
- REMOVE CRANKSHAFT PULLEY
- Install SST to the crankshaft pulley.
- SST: 09213-80010
- 90179-10016
- 09213-08010
- 09213-08110
HINT:
Position the projections on SST in the direction as shown in the illustration to prevent SST from separating from the crankshaft pulley.
TEXT IN ILLUSTRATION*1 Claw - SST: 09213-80010
- Using SST, hold the crankshaft pulley and loosen the crankshaft pulley set bolt.
- SST: 09213-80010
- 90179-10016
- 09213-08010
- 09213-08110
TEXT IN ILLUSTRATION*a Hold *b Turn - SST: 09213-80010
- Remove the crankshaft pulley.
- Remove the O-ring and crankshaft pulley spacer.
- Install SST to the crankshaft pulley.
- REMOVE TIMING CHAIN OR BELT COVER OIL SEAL
- Using a screwdriver with its tip wrapped in protective tape, pry out the timing chain or belt cover oil seal.TEXT IN ILLUSTRATION
*1 Protective Tape NOTE:After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper.
HINT:
Tape the screwdriver tip before use.
- Using a screwdriver with its tip wrapped in protective tape, pry out the timing chain or belt cover oil seal.
- REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
- Remove the 32 bolts.
- Using a screwdriver with its tip wrapped in protective tape, remove the timing chain or belt cover sub-assembly by prying between the timing chain or belt cover sub-assembly and cylinder head or cylinder block.TEXT IN ILLUSTRATION
*1 Protective Tape - - NOTE:Be careful not to damage the contact surfaces of the cylinder head, cylinder block or chain cover.
- Remove the 4 O-rings.
- Remove the 32 bolts.
- MAKE PAINT MARKS
HINT:
If the alignment marks are difficult to identify during the work, mark the alignment marks with paint at the positions shown in the illustration, for easier recognition.
TEXT IN ILLUSTRATION*a Triangular Mark *b Engraved Line *c Oval Mark *d Crankshaft Timing Gear key - REMOVE CHAIN SUB-ASSEMBLY (for Bank 1) WARNING:
Do not remove the chain sub-assembly from bank 2 at the same time as the chain sub-assembly is being removed from bank 1. Otherwise, the camshaft on bank 2 may turn suddenly, which is dangerous.
- Temporarily install the crankshaft pulley spacer and crankshaft pulley.
- Using SST, turn the crankshaft pulley clockwise until the alignment marks on the camshaft timing intake gear assembly RH and the camshaft timing exhaust gear assembly RH, and the crankshaft pulley pin hole are aligned at the positions shown in the illustration.
- SST: 09960-10010
- 09962-01000
- 09963-01000
HINT:
At this time, the alignment mark on the crankshaft timing gear or sprocket and the crankshaft timing gear key are at the positions shown in the illustration.
TEXT IN ILLUSTRATION*a Alignment Mark *b Crankshaft Pulley Pin Hole *c Crankshaft Timing Gear key - SST: 09960-10010
- Remove the crankshaft pulley and crankshaft pulley spacer.
- Push down the chain tensioner slipper and retain the plunger by inserting a 2.5 mm (0.098 in.) diameter hexagonal wrench into the No. 1 chain tensioner assembly through the stopper plate.
- Remove the 2 bolts and No. 1 chain tensioner assembly.
- Remove the chain tensioner slipper.
- Using a 5 mm hexagonal wrench, remove the bolt and No. 1 chain vibration damper.
- Remove the chain sub- assembly (for bank 1).NOTE:
- With the chain sub- assembly (for bank 1) removed, the valve heads may contact each other if the camshafts are turned, causing the valve stems to bend.
- To avoid this, do not turn the intake camshaft RH and the exhaust camshaft RH more than zero-lift range (The range where camshafts can be turned lightly by hand).
HINT:
Arrange the removed parts in the correct order.
- Temporarily install the crankshaft pulley spacer and crankshaft pulley.
- REMOVE CHAIN SUB-ASSEMBLY (for Bank 2)
- Temporarily install the crankshaft pulley spacer and crankshaft pulley.
- Using SST, turn the crankshaft pulley clockwise until the alignment marks on the camshaft timing intake gear assembly LH and the camshaft timing exhaust gear assembly LH, and the crankshaft pulley pin hole are aligned at the positions shown in the illustration.
- SST: 09960-10010
- 09962-01000
- 09963-01000
TEXT IN ILLUSTRATION*a Alignment Mark *b Crankshaft Pulley Pin Hole *c Crankshaft Timing Gear key *d Cylinder Block Guide Pin HINT:
At this time, the crankshaft timing gear key is at the position shown in the illustration.
- SST: 09960-10010
- Remove the crankshaft pulley and crankshaft pulley spacer.
- Push the chain tensioner slipper and retain the plunger by inserting an approximately 1 mm (0.039 in.) diameter wire into the No. 2 chain tensioner assembly through the stopper plate.
- Remove the 2 bolts and No. 2 chain tensioner assembly.
- Remove the chain tensioner slipper.
- Remove the O-ring from the cylinder block.
- Using a 5 mm socket hexagon wrench, remove the bolt and No. 1 chain vibration damper.
- While releasing the tension of chain sub-assembly using SST, remove the chain sub-assembly.
- SST: 09960-10010
- 09962-01000
- 09963-00700
WARNING:Make sure to use SST. Never carry out the work using only your hands.
NOTE:- With the chain sub-assembly (for bank 2) removed, the valve heads may contact each other if the camshafts are turned, causing the valve stems to bend. To avoid this, do not turn the exhaust camshaft LH more than zero-lift rang (The range where the camshaft can be turned lightly by hand).
- At this time, No. 1 and No. 4 pistons are located near TDC. If the intake camshaft is turned, the valves may come into contact with the piston, causing the valve stems to bend. To avoid this, do not turn the intake camshaft LH.
HINT:
Arrange the removed parts in the correct order.
- SST: 09960-10010
- ROTATE CRANK SHAFT AND CAMSHAFT
See step 29
- REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
- REMOVE CAMSHAFT TIMING INTAKE GEAR ASSEMBLY RH
See step 31
- REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY RH
See step 32
- REMOVE CAMSHAFT TIMING INTAKE GEAR ASSEMBLY LH
See step 33
- REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY LH
See step 34
- REMOVE SPARK PLUG
- Using a 14 mm spark plug wrench, remove the 4 spark plugs.
- REMOVE INJECTOR DRIVER BRACKET
- REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH
- Operate the engine stand so that the bank 1 side faces upward.
- Remove the 8 bolts.
- Using a screwdriver with its tip wrapped in protective tape, remove the cylinder head cover sub-assembly RH.NOTE:
Do not damage the camshaft housing sub-assembly RH, cam caps and cylinder head cover sub-assembly RH.
- Remove the cylinder head cover gasket.
- Remove the 2 spark plug tube gaskets.NOTE:
When removing the seal packing left on the camshaft housing sub-assembly RH using a scraper, use special care not to damage the camshafts.
- REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH NOTE:
Do not remove the intake and exhaust camshafts first as it may cause a deformation of the cylinder head sub-assembly.
- Loosen the 9 bolts in the order shown in the illustration and remove them.
- Using a screwdriver with its tip wrapped in protective tape, remove the camshaft housing sub-assembly RH.NOTE:
Do not damage the cylinder head sub-assembly RH and camshaft housing sub-assembly RH.
- Remove the 2 O-rings and 8 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.
HINT:
Arrange the removed parts in the correct order.
- Remove the 8 valve adjusting shims and 8 roller rocker arm pivots from the cylinder head sub-assembly.
HINT:
Arrange the removed parts in the correct order.
- Loosen the 9 bolts in the order shown in the illustration and remove them.
- REMOVE CYLINDER HEAD SUB-ASSEMBLY RH
See step 2
- REMOVE CYLINDER HEAD GASKET
See step 3
- REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
- Operate the engine stand so that the bank 2 side faces upward.
- Remove the 8 bolts.
- Using a screwdriver with its tip wrapped in protective tape, remove the cylinder head cover sub-assembly LH.NOTE:
Do not damage the camshaft housing sub-assembly LH, cam caps and cylinder head cover sub-assembly LH.
- Remove the cylinder head cover gasket.
- Remove the 2 spark plug tube gaskets.NOTE:
When removing the seal packing left on the camshaft housing sub-assembly LH using a scraper, use special care not to damage the camshafts.
- REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH NOTE:
Do not remove the intake and exhaust camshafts first as it may cause a deformation of the camshaft housing sub-assembly LH.
- Loosen the 9 bolts in the order shown in the illustration and remove them.
- Using a screwdriver with its tip wrapped in protective tape, remove the camshaft housing sub-assembly LH.NOTE:
Do not damage the cylinder head sub-assembly LH and camshaft housing sub-assembly LH.
- Remove the 2 O-rings and 8 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly LH.
HINT:
Arrange the removed parts in the correct order.
- Remove the 8 valve adjusting shims and 8 roller rocker arm pivots from the cylinder head sub-assembly LH.
HINT:
Arrange the removed parts in the correct order.
- Loosen the 9 bolts in the order shown in the illustration and remove them.
- REMOVE CYLINDER HEAD SUB-ASSEMBLY LH
See step 5
- REMOVE NO. 2 CYLINDER HEAD GASKET
See step 6
- REMOVE NO. 2 ENGINE HANGER
- Remove the 2 bolts and No. 2 engine hanger from the cylinder block (for bank 1).
- REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
- REMOVE OIL STRAINER SUB-ASSEMBLY
- REMOVE OIL PAN SUB-ASSEMBLY
- Remove the 13 bolts.TEXT IN ILLUSTRATION
*a Use a TORX Socket Wrench T45 - Using a screwdriver with its tip wrapped in protective tape, remove the oil pan sub-assembly.NOTE:
Do not damage the cylinder block and oil pan sub-assembly.
- Remove the 3 O-rings from the cylinder block.
- Remove the 4 bolts and baffle plate from the oil pan sub-assembly.
- Remove the 2 stud bolts from the oil pan sub-assembly.
- Remove the 13 bolts.
- REMOVE CAMSHAFT BEARING CAP (for Bank 1)
See step 44
- REMOVE CAMSHAFT (for Bank 1)
See step 45
- REMOVE OIL CONTROL VALVE FILTER (for Bank 1)
- REMOVE OIL SPACER RH
- REMOVE CAMSHAFT OIL FEED PIPE SUB-ASSEMBLY (for Automatic Transmission)
- REMOVE HOLE PLUG (for Manual Transmission)
- REMOVE CAMSHAFT BEARING CAP (for Bank 2)
See step 46
- REMOVE CAMSHAFT (for Bank 2)
See step 47
- REMOVE OIL CONTROL VALVE FILTER (for Bank 2)
- REMOVE OIL SPACER LH