Part 1

ENGINE UNIT

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

DISASSEMBLY (STEPS 1-26)
1. REMOVE OIL FILLER CAP SUB-ASSEMBLY
2. REMOVE RADIATOR CAP SUB-ASSEMBLY
3. REMOVE SPARK PLUG
4. REMOVE OIL PAN DRAIN PLUG
a. Remove the drain plug and gasket.





5. REMOVE VENTILATION VALVE SUB-ASSEMBLY
a. Remove the ventilation valve.





6. REMOVE CAMSHAFT POSITION SENSOR
a. Remove the 4 bolts and 4 sensors.





7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Remove the 4 bolts and 4 oil control valves.





8. REMOVE CRANKSHAFT POSITION SENSOR
a. Remove the bolt and sensor.





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





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





11. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Remove the water drain cocks from the cylinder block.
b. Remove the water drain cock plugs from the water drain cocks.
12. REMOVE OIL FILTER ELEMENT (for 2WD)





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

HINT: Place a container for oil to be drained before removing the cap.





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.

13. REMOVE OIL FILTER ELEMENT (for 4WD)





a. Connect a hose with an inside diameter of 15 mm (0.59 inch) to the pipe.





b. Remove the oil filter drain plug.





c. Install the pipe to the oil filter cap.

NOTICE: If the O-ring is removed with the drain plug, install the O-ring together with the pipe.

HINT: Use a container to catch the draining oil.





d. Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring, as shown in the illustration.





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





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

NOTICE: Be sure to remove the O-ring (for the cap) by hand, without using any tools, to prevent damage to the groove for the O-ring on the cap.





14. 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.
15. 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)
16. REMOVE WATER INLET ASSEMBLY





a. Separate the 3 water by-pass hoses.





b. Remove the 4 bolts, nut and water inlet.





c. Remove the 2 O-rings.





d. Remove the 3 water by-pass hoses.





17. REMOVE WATER INLET WITH THERMOSTAT SUB ASSEMBLY
a. Remove the 3 nuts and water inlet with thermostat.
b. Remove the gasket from the water inlet.
18. REMOVE REAR WATER BY-PASS JOINT





a. Remove the 2 bolts, 4 nuts and water by-pass joint.





b. Remove the 2 gaskets and O-ring.
19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)





a. Remove the 14 bolts, head cover and gasket.





b. Remove the 3 gaskets.
20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
a. For 4WD:
1. Remove the 2 bolts, and No. 2 engine hanger.





b. Remove the 12 bolts, head cover and gasket.

NOTICE: The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the head cover.





c. Remove the 3 gaskets.





21. REMOVE SPARK PLUG TUBE GASKET
a. Pry up the claws of the ventilation baffle plate.

NOTICE: Do not deform the claws of the baffle plate more than necessary.

b. Remove the 6 gaskets from the cylinder head covers.

NOTICE:
^ As much as possible prevent the plug tube gaskets from being deformed. The removed gaskets will be used when reinstalling the gaskets.
^ Do not damage the connection of the cylinder head cover.

22. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY





a. For 2WD:
1. Remove the 15 bolts and 2 nuts.





b. For 4WD:
1. Remove the 14 bolts and 2 nuts.





c. Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.
SST 09032-00100

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





23. REMOVE OIL WITH STRAINER PIPE SUB-ASSEMBLY (for 4WD)
a. Remove the 3 nuts, oil with strainer pipe and gasket.
24. REMOVE OIL PAN SUB-ASSEMBLY





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.





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.
25. REMOVE OIL STRAINER SUB-ASSEMBLY
a. For 2WD





1. Remove the 3 nuts, oil strainer and gasket.





2. Remove the 8 bolts and baffle plate.
b. For 4WD





1. Remove the bolt, 2 nuts, oil strainer and gasket.





2. Remove the 7 bolts and baffle plate.
26. REMOVE ENGINE REAR OIL SEAL RETAINER





a. Remove the 6 bolts.





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

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

HINT: Tape the screwdriver tip before use.