7GR-FKS ENGINE MECHANICAL  ENGINE UNIT  DISASSEMBLY  

12185 1.REMOVE OIL FILLER CAP HOUSING

a.

Remove the oil filler cap sub-assembly.

b.

Remove the 2 nuts, oil filler cap housing assembly and gasket.

19100P 2.REMOVE SPARK PLUG

12101A 3.REMOVE OIL PAN DRAIN PLUG

12601B 4.REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/o Secondary Air Injection System)

12601B 5.REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/o Secondary Air Injection System)

a.

Remove the 2 clips and No. 1 engine cover sub-assembly.

12204 6.REMOVE PCV VALVE SUB-ASSEMBLY

15370B 7.REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)

15370B 8.REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)

15370C 9.REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)

15370C 10.REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)

11.REMOVE VVT SENSOR (for Intake Side of Bank 1)

12.REMOVE VVT SENSOR (for Exhaust Side of Bank 1)

13.REMOVE VVT SENSOR (for Intake Side of Bank 2)

14.REMOVE VVT SENSOR (for Exhaust Side of Bank 2)

11401G 15.REMOVE CRANKSHAFT POSITION SENSOR

11415 16.REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

a.

Remove the cylinder block water drain cock plug from the cylinder block water drain cock sub-assembly.

b.

Remove the water cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.

17.REMOVE OIL FILTER ELEMENT

15609 18.REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

15710 19.REMOVE OIL COOLER ASSEMBLY

13471 20.REMOVE CRANKSHAFT PULLEY

16031 21.REMOVE WATER INLET SUB-ASSEMBLY WITH THERMOSTAT

a.

Remove the 2 bolts, nut, water inlet sub-assembly with thermostat and gasket.

16331 22.REMOVE WATER OUTLET

a.

Remove the 2 bolts and water outlet.

b.

Remove the O-ring.

16356 23.REMOVE REAR WATER BY-PASS JOINT

a.

Detach the 2 clamps and disconnect the No. 5 engine wire.

b.

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

c.

Remove the O-ring from the No. 1 water outlet pipe.

d.

Remove the 2 O-rings from the rear water by-pass joint.

24.REMOVE FUEL PUMP SPACER GASKET

11201 25.REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

11202 26.REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

27.REMOVE OIL FILLER STUD BOLT

a.

Remove the 2 oil filler stud bolts from the cylinder head cover sub-assembly LH.

11193 28.REMOVE SPARK PLUG TUBE GASKET

a.

Remove the 6 spark plug tube gaskets.

HINT:

Be careful not to damage the gasket when removing it as the removed gasket needs to be used when installing a new one.

12101A 29.REMOVE OIL PAN DRAIN PLUG

12102A 30.REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

15104 31.REMOVE OIL STRAINER SUB-ASSEMBLY

89491 32.REMOVE ENGINE OIL LEVEL SENSOR

15367 33.REMOVE OIL LEVEL SENSOR BRACKET

12101 34.REMOVE OIL PAN SUB-ASSEMBLY

12121 35.REMOVE NO. 1 OIL PAN BAFFLE PLATE

a.

Remove the 8 bolts and No. 1 oil pan baffle plate.

11381 36.REMOVE REAR ENGINE OIL SEAL RETAINER

a.

Remove the 6 bolts.

b.

0,0 0,0 false

Pry

Using a screwdriver, pry out the rear engine oil seal retainer.

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

11381A 37.REMOVE REAR CRANKSHAFT OIL SEAL

a.

0.371,1.743 0.715,1.961 0.343,0.218 10 *a 0.898,1.673 0.599,1.859 false 0.599,1.859 1.589,1.988 false 1.414,1.26 0.633,0.871 false 0.41,0.776 0.684,1.036 0.274,0.260 10 *b

*a	Wooden Block
*b	Protective Tape

Place the rear engine oil seal retainer on wooden blocks.

NOTICE:

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

b.

Using a screwdriver and a hammer, tap out the rear crankshaft oil seal.

HINT:

Tape the screwdriver tip before use.

11310 38.REMOVE TIMING CHAIN COVER ASSEMBLY

16100 39.REMOVE ENGINE WATER PUMP ASSEMBLY

11301C 40.REMOVE FRONT CRANKSHAFT OIL SEAL

41.SET NO. 1 CYLINDER TO TDC/COMPRESSION

a.

Temporarily install the crankshaft pulley set bolt.

b.

1.771,2.219 2.292,1.667 2.292,1.667 2.844,1.667 true 0.99,0.917 1.24,0.729 1.24,0.729 2.396,0.729 true 1.531,1.708 2.156,0.74 false 2.49,0.625 2.729,0.823 0.24,0.198 10 true *a 2.885,1.573 3.156,1.792 0.271,0.219 10 true *1

*1	Crankshaft Pulley Set Key
*a	Center Mark

Set the crankshaft pulley set key to the RH block bore center mark (TDC/compression).

c.

1.396,0.698 1.865,1.177 false 1.438,0.406 1.865,1.177 false 2.448,0.427 1.865,1.177 false 2.521,0.875 1.865,1.177 false 1.292,3.802 1.823,4.156 false 1.365,3.333 1.823,4.156 false 2.333,3.302 1.823,4.156 false 2.375,3.625 1.823,4.156 false 1.781,1.198 2.031,1.458 0.25,0.26 10 true *a 1.74,4.167 2,4.427 0.26,0.26 10 true *a

*a	Timing Mark

Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the camshaft bearing cap as shown in the illustration.

If not, turn the crankshaft 1 revolution (360°) and align the timing marks as described above.

13540 42.REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

a.

1.146,1.188 1.448,1.76 1.448,1.76 2.635,1.177 false 2.667,1.729 3.021,1.729 false 1.146,0.875 0.729,0.167 0.729,0.167 0.635,0.167 true 2.823,0.854 2.479,0.135 2.479,0.135 2.344,0.135 false 0.427,0.094 0.594,0.271 0.167,0.177 10 true *1 1.375,1.792 1.677,2.01 0.302,0.219 10 true *2 3.052,1.635 3.229,1.813 0.177,0.177 10 true *3 2.125,0.073 2.292,0.25 0.167,0.177 10 true *1

*1	Plunger
*2	Stopper Plate
*3	Pin

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 pin of 1.27 mm (0.0500 in.) diameter into the hole of the stopper plate.

c.

Remove the 2 bolts and No. 1 chain tensioner assembly.

13559 43.REMOVE CHAIN TENSIONER SLIPPER

13506 44.REMOVE CHAIN SUB-ASSEMBLY

a.

2.094,0.75 1.969,0.75 1.969,0.75 1.969,1.042 true 2.26,0.615 2.417,0.51 2.417,0.51 2.531,0.51 true 1.885,1.042 2.115,1.271 0.229,0.229 10 true *a 2.573,0.417 2.854,0.677 0.281,0.26 10 true *b 0.615,0.917 0.958,1.177 0.344,0.26 10 false 10°

*a	Timing Mark
*b	Center Line

Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing gear or sprocket.

b.

Remove the crankshaft pulley set bolt.

c.

Remove the chain sub-assembly from the crankshaft timing gear or sprocket and place it on the crankshaft.

d.

0.118,0 0.440,0.253 0.323,0.253 10 *A

*A	for Bank 1

Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks.

e.

Remove the chain sub-assembly.

13530 45.REMOVE IDLE SPROCKET ASSEMBLY

a.

Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft.

13561 46.REMOVE NO. 1 CHAIN VIBRATION DAMPER

a.

Remove the 2 bolts and No. 1 chain vibration damper.

13562 47.REMOVE NO. 2 CHAIN VIBRATION DAMPER

a.

Remove the 2 No. 2 chain vibration dampers.

13521 48.REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

a.

Remove the crankshaft timing gear or sprocket from the crankshaft.

b.

Remove the 2 crankshaft timing gear keys from the crankshaft.

49.REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

13550 50.REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

51.REMOVE CAMSHAFT BEARING CAP (for Bank 1)

23476 52.REMOVE FUEL PUMP LIFTER HOUSING

13511 53.REMOVE CAMSHAFT

13512 54.REMOVE NO. 2 CAMSHAFT

11103C 55.REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

56.REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

13560A 57.REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

58.REMOVE CAMSHAFT BEARING CAP (for Bank 2)

13053 59.REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

13054 60.REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

11104A 61.REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

15678E 62.REMOVE OIL CONTROL VALVE FILTER LH

a.

Remove the oil control valve filter LH from the camshaft bearing cap.

15678D 63.REMOVE OIL CONTROL VALVE FILTER RH

11159F 64.REMOVE CAMSHAFT BEARING CAP OIL HOLE GASKET

a.

Remove the camshaft bearing cap oil hole gasket from the No. 6 camshaft bearing cap.

b.

Remove the camshaft bearing cap oil hole gasket from the No. 7 camshaft bearing cap.

13801 65.REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

13750 66.REMOVE VALVE LASH ADJUSTER ASSEMBLY

13716 67.REMOVE VALVE STEM CAP

11101 68.REMOVE CYLINDER HEAD SUB-ASSEMBLY

11115 69.REMOVE CYLINDER HEAD GASKET

11102 70.REMOVE CYLINDER HEAD LH

11116 71.REMOVE NO. 2 CYLINDER HEAD GASKET

82125N 72.REMOVE NO. 5 ENGINE WIRE

a.

Disconnect the 2 connectors.

b.

Detach the 2 clamps and remove the No. 5 engine wire.

89615 73.REMOVE KNOCK CONTROL SENSOR

16332 74.REMOVE NO. 1 WATER OUTLET PIPE

a.

Remove the 2 bolts and No. 1 water outlet pipe.

75.REMOVE CYLINDER BLOCK WATER JACKET SPACER

a.

Remove the 2 cylinder block water jacket spacers from the cylinder block sub-assembly.

NOTICE:

Be sure to remove the water jacket spacers. If not, they may fall and become damaged when the cylinder block sub-assembly is inverted.

11114A 76.REMOVE STRAIGHT PIN

11151 77.REMOVE RING PIN