Part 1

ENGINE UNIT

Components:

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 parts.

1. REMOVE SPARK PLUG
2. REMOVE OIL FILLER CAP SUB-ASSEMBLY
3. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.

4. REMOVE NO.2 IDLER PULLEY SUB-ASSEMBLY
a. Remove the pulley bolt, cover plate and idler pulley.

5. REMOVE TIMING BELT COVER SUB-ASSEMBLY NO.2
a. Remove the 2 bolts and timing belt cover.

6. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the bolt, 2 nuts and belt tensioner.

7. REMOVE IDLER PULLEY ASSEMBLY
a. Remove the 2 bolts, 2 nuts and idler pulley.

8. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY
a. Using SST, remove the damper bolt.
SST 09213-70011, 09330-00021

b. Using SST, remove the damper.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05021)

9. REMOVE NO.1 TIMING BELT COVER
a. Remove the 4 bolts and timing belt cover.

10. REMOVE TIMING GEAR COVER SPACER
11. REMOVE CRANKSHAFT POSITION SENSOR PLATE

12. REMOVE TIMING BELT
a. If planning to reuse the belt, check the installation marks on the timing belt.
(1) Check that there are 3 installation marks on the belt by turning the crankshaft as shown in the illustration. If the installation marks have disappeared, place new installation marks on the belt before removing each part.

b. Set the No.1 cylinder to approximately 45° BTDC/compression.
(1) Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body

(2) Check that the timing marks of the camshaft timing pulleys and timing belt plates are aligned. If not, turn the crankshaft 1 revolution (360°).

(3) Check that the timing marks of the camshaft timing pulleys and timing belt plates are aligned. If not, turn the crankshaft 1 revolution (360°).

NOTICE: With the timing belt disengaged, the crankshaft damper must be at the correct angle to avoid damage in a later step.

c. Alternately loosen the 2 bolts. Then remove the 2 bolts, belt tensioner and dust boot.

d. Using SST, loosen the tension between the camshaft timing pulley (RH bank) and crankshaft timing pulley by slightly turning the camshaft timing pulley (RH bank) counterclockwise.
SST 09960-10010 (09962-01000, 09963-00350)
e. Disconnect the belt from the timing belt idler No.1, and remove the belt.

13. REMOVE NO.1 TIMING BELT IDLER SUB-ASSEMBLY
a. Using a 10 mm hexagon wrench, remove the bolt, idler and plate washer.

14. REMOVE NO.2 TIMING BELT IDLER SUB-ASSEMBLY
a. Remove the bolt and idler.

15. REMOVE CRANKSHAFT TIMING PULLEY
a. Using SST, remove the timing pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010)

NOTICE: Do not turn the timing pulley.

16. REMOVE CAMSHAFT TIMING PULLEY
a. Remove the 4 bolts and timing pulley.

LH Bank:

17. REMOVE CAMSHAFT TIMING PULLEY SUB-ASSEMBLY LH
Remove the 4 bolts and timing pulley.

18. REMOVE CAMSHAFT

NOTICE: Since 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 receiving 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 camshafts of the RH bank.
(1) Bring the service bolt hole of the sub gear upward by turning the hexagon head portion of the No.2 camshaft with a wrench.
(2) Secure the sub gear to the main gear with a service bolt.

Recommended Service Bolt:

HINT: When removing the camshaft, make sure that the torsional spring force of the sub gear has been eliminated by the above operation.

(3) Set a wrench to the hexagon head portion of the No.2 camshaft. Rotate the wrench so that the timing mark (1 dot mark) on the camshaft main gear is moved approximately 10°, as shown in the illustration.

(4) Uniformly loosen the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
(5) Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and 2 camshafts.

19. REMOVE NO.3 CAMSHAFT SUB-ASSEMBLY

NOTICE: Since 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 receiving 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 camshafts of the LH bank.
(1) Bring the service bolt hole of the sub gear upward by turning the hexagon head portion of the exhaust No.4 camshaft with a wrench.
(2) Secure the sub gear to the main gear with a service bolt.

Recommended Service Bolt:

HINT: When removing the camshaft, make sure that the torsional spring force of the sub gear has been eliminated by the above operation.

(3) Set a wrench to the hexagon head portion of the No.4 camshaft. Rotate the wrench so that the timing marks (2 dot marks each) on the camshaft drive and driven main gears are aligned, as shown in the illustration.

(4) Uniformly loosen the 22 bearing cap bolts in several passes, in the sequence shown in the illustration.
(5) Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and 2 camshafts.

NOTICE:
^ Do not forcibly pry the camshaft with a tool.
^ Do not damage the reception part of the thrust on the cylinder head side.

20. REMOVE SEMICIRCULAR PLUG
21. REMOVE REAR NO.2 TIMING BELT PLATE RH
a. Remove the 2 bolts and timing belt plate.

22. REMOVE REAR TIMING BELT PLATE RH
a. Remove the bolt, stud bolt and timing belt plate.

23. REMOVE REAR NO.2 TIMING BELT PLATE LH
a. Remove the 2 bolts and timing belt plate.

24. REMOVE REAR TIMING BELT PLATE LH
a. Remove the bolt, stud bolt and timing belt plate.

RH Bank:

25. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a. Uniformly loosen 10 cylinder head bolts on one side of each cylinder head in several passes, in the sequence shown in the illustration.

RH Bank:

NOTICE:
^ Cylinder head warpage or cracking could result from removing bolts in incorrect order.
^ Be careful not to drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

RH Bank:

LH Bank:

26. REMOVE CYLINDER HEAD LH
a. Uniformly loosen 10 cylinder head bolts on one side of each cylinder head in several passes, in the sequence shown in the illustration.

LH Bank:

b. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

HINT: If the cylinder head cannot be removed, pry between the cylinder head and cylinder block with a screwdriver.

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

27. REMOVE WATER PUMP ASSEMBLY
a. Remove the 5 bolts, 2 stud bolts, nut, water pump and gasket.

28. REMOVE NO.2 OIL PAN SUB-ASSEMBLY
29. REMOVE OIL PAN BAFFLE PLATE
30. REMOVE OIL PAN SUB-ASSEMBLY
31. REMOVE OIL STRAINER SUB-ASSEMBLY
32. REMOVE OIL PUMP ASSEMBLY

33. REMOVE ENGINE REAR OIL SEAL RETAINER
a. Remove the 7 bolts.
b. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and crankshaft bearing cap.
c. Remove the O-ring.