Part 1

4GR-FSE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

DISASSEMBLY

Part 1 of 2

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY
(a) Remove the oil filler cap and gasket.
2. REMOVE RADIATOR CAP SUB-ASSEMBLY
(a) Remove the radiator cap.
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.
NOTE:
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 in.) to the pipe.

(b) Remove the oil filter drain plug.

(c) Install the pipe to the oil filter cap.
NOTE:
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.
NOTE:
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
SST: 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 SUB-ASSEMBLY

(a) Separate the 3 water by-pass hoses.

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

(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.
NOTE:
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.

(a) Pry up the claws of the ventilation baffle plate.
NOTE:
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 oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.
NOTE:
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.
NOTE:
Be careful not to damage the contact surfaces of the cylinder block and oil pan.
HINT:
Tape the screwdriver tip before use.

(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.
NOTE:
Be careful not to damage the engine rear oil seal retainer.
HINT:
Tape the screwdriver tip before use.

27. REMOVE ENGINE REAR OIL SEAL

(a) Place the oil seal retainer on wooden blocks.
NOTE:
Be careful not to damage the engine rear oil seal retainer.

(b) Using a screwdriver and a hammer, tap out the oil seal.
HINT:
Tape the screwdriver tip before use.

28. REMOVE WATER PUMP ASSEMBLY

(a) Remove the 16 bolts, water pump and gasket.
29. REMOVE TIMING CHAIN 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.
NOTE:
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.
30. REMOVE TIMING CHAIN CASE OIL SEAL

(a) Using a screwdriver, pry out the oil seal.
HINT:
Tape the screwdriver tip before use.

31. 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.
32. 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.

(c) Remove the 2 bolts and chain tensioner.
33. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the chain tensioner slipper.
34. REMOVE CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket.
(b) Remove the pulley set bolt.

(d) 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 banks.
(e) Remove the chain.
35. REMOVE IDLE SPROCKET ASSEMBLY

(a) Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, sprocket and No. 1 idle gear shaft.
36. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and vibration damper.
37. REMOVE NO. 2 CHAIN VIBRATION DAMPER

(a) Remove the 2 vibration dampers.
38. REMOVE CRANKSHAFT TIMING SPROCKET

(a) Remove the crankshaft timing sprocket from the crankshaft.
(b) Remove the 2 pulley set keys from the crankshaft.
39. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

Continued in Part 2 Part 2