Part 1

ENGINE UNIT

Components:

Components 2wd:

Components 4wd:

Components:

DISASSEMBLY
1. REMOVE OIL FILTER CAP SUB-ASSEMBLY
a. Remove the oil filler cap sub-assembly

2. REMOVE RADIATOR CAP SUB-ASSEMBLY
a. Remove the radiator cap sub-assembly.

3. REMOVE NO.1 ENGINE HANGER
a. Remove the 2 bolts and engine hanger.

4. REMOVE NO.2 ENGINE HANGER
a. Remove the 2 bolts and engine hanger No.2.

5. REMOVE SPARK PLUG
6. REMOVE OIL PAN DRAIN PLUG
a. Remove the drain plug and gasket.

7. REMOVE VENTILATION VALVE SUB-ASSEMBLY
a. Remove the ventilation valve sub-assembly.

8. REMOVE CAMSHAFT POSITION SENSOR
a. Remove the 4 bolts and 4 camshaft position sensors.

9. REMOVE CAM TIMING OIL CONTROL VALVE ASSEMBLY
a. Remove the 4 bolts and 4 camshaft timing oil control valves.

10. REMOVE CRANKSHAFT POSITION SENSOR
a. Remove the bolt and crankshaft position sensor.

11. REMOVE NO.1 OIL PIPE
a. Remove the oil check valve bolt, oil pipe union, and oil pipe No.1.
b. Remove the oil control valve filter LH and gaskets.

12. REMOVE NO.2 OIL PIPE
a. Remove the oil check valve bolt, oil pipe union, and oil pipe No.2.
b. Remove the oil control valve filter RH and gaskets.

13. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Remove the water drain cock sub-assembly from the cylinder block.
b. Remove the water drain cock plugs from the water drain cock sub-assembly.

14. REMOVE OIL FILTER ELEMENT (for 2WD)
a. Using SST, remove the oil filter cap.
SST09228-06501

b. Remove the oil filter element and O-ring from the oil filter cap.

NOTICE: Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.

15. REMOVE OIL FILTER ELEMENT (for 4WD)
a. Remove the oil filter drain plug.

b. Using SST, remove the oil filter cap.
SST 09228-06501

c. Remove the oil filter element and O-ring from the oil filter cap.

NOTICE: Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.

16. REMOVE OIL FILTER BRACKET (for 4WD)
a. Remove the bolt, 2 nuts and oil filter bracket from the oil pan.
b. Remove the gasket from the oil filter bracket.

17. REMOVE CRANKSHAFT PULLEY
a. Using SST, loosen the crankshaft pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021

b. Using SST, remove the crankshaft pulley bolt and crankshaft pulley
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)

18. REMOVE WATER INLET
a. Remove the 3 water by-pass hoses.
b. Remove the 4 bolts, nut and water inlet.
c. Remove the O-rings.

19. REMOVE WITH THERMOSTAT WATER INLET SUB-ASSEMBLY
a. Remove the 3 nuts and with thermostat water inlet sub-assembly.
b. Remove the gasket from the with thermostat water inlet sub-assembly.

20. REMOVE WATER BY-PASS JOINT RR
a. Remove the 2 bolts, 4 nuts and water by-pass joint RR.
b. Remove the 2 gaskets and O-ring.

21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
a. Remove the 12 bolts, head cover and gasket.

22. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
a. Remove the 14 bolts, head cover and gasket.

2wd:

23. REMOVE NO.2 OIL PAN SUB-ASSEMBLY (for 2WD)
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 oil pan sub-assembly No.2.
SST 09032-00100

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

4wd:

24. REMOVE NO.2 OIL PAN SUB-ASSEMBLY (for 4WD)
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 oil pan sub-assembly No.2.
SST 09032-00100

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

4wd:

25. REMOVE OIL STRAINER SUB-ASSEMBLY (for 4WD)
a. Remove the 3 nuts, oil strainer sub-assembly and gasket.

2wd:

26. REMOVE OIL PAN SUB-ASSEMBLY (for 2WD)
a. Remove the 16 bolts and 2 nuts.

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

2wd:

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.

c. Remove the 2 O-rings.

27. REMOVE OIL PAN SUB-ASSEMBLY (for 4WD)
a. Remove the 16 bolts and 2 nuts.

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

4wd:

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.

c. Remove the 2 O-rings.

2wd:

28. REMOVE OIL STRAINER SUB-ASSEMBLY (for 2WD)
a. Remove the 3 nuts, oil strainer and gasket.

4wd:

29. REMOVE OIL STRAINER SUB-ASSEMBLY (for 4WD)
a. Remove the 2 nuts, oil strainer and gasket.

30. REMOVE OIL PAN BAFFLE PLATE
a. Remove the 8 bolts and oil pan baffle plate.

31. REMOVE REAR ENGINE 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.

32. REMOVE WATER PUMP ASSEMBLY
a. Remove the 16 bolts, water pump and gasket.

33. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove the 16 bolts and 2 nuts as shown in the illustration.

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 cylinder head, cylinder block and chain cover.

HINT: Tape the screwdriver tip before use.

c. Remove the 4 bolts, chain cover plate and gasket.
d. Remove the gasket.

34. SET NO.1 CYLINDER TO TDC/COMPRESSION
a. Temporarily tighten the pulley set bolt.
b. Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC/compression).

c. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.

35. REMOVE NO.1 CHAIN TENSIONER ASSEMBLY
a. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
b. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate's hole.

RH:

c. Remove the 2 bolts and chain tensioner.

36. REMOVE CHAIN TENSIONER SLIPPER
a. Remove the chain tensioner slipper.

37. REMOVE CHAIN SUB-ASSEMBLY
a. Turn the crankshaft counterclockwise 100 to loosen the chain of the crankshaft timing gear.
b. Remove the chain from the crank timing gear and place it on the crankshaft.
c. Turn the camshaft timing gear assembly on the RH bank clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the center banks.
d. Remove the chain.

38. REMOVE IDLE SPROCKET ASSEMBLY
a. Using a 10 mm hexagon wrench, remove the idle gear shaft No.2, sprocket and idle gear shaft No.1.

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

40. REMOVE NO.2 CHAIN VIBRATION DAMPER
a. Remove the 2 chain vibration damper No.2.

41. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
a. Remove the pulley set bolt.
b. Remove the crankshaft timing gear from the crankshaft.
c. Remove the 2 pulley set keys from the crankshaft.

42. REMOVE NO.2 CAMSHAFT TIMING GEARS AND CHAIN (for Bank 1)
a. While raising up the chain plunger, insert a pin of 1.0 mm (0.039 inch) into the hole to fix the plunger.

b. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.

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

c. Remove the No.2 chain.

43. REMOVE NO.2 CHAIN TENSIONER ASSEMBLY
a. Remove the bolt and chain tensioner No.2.