Part 1

1NR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

1. REMOVE REAR ENGINE OIL SEAL

(a) Using a knife, cut off the oil seal lip.





Text in Illustration





(b) Using a screwdriver with its tip wrapped with protective tape, pry out the rear engine oil seal.

2. REMOVE OIL FILLER CAP SUB-ASSEMBLY





(a) Remove the oil filler cap.

3. REMOVE OIL FILLER CAP GASKET

(a) Remove the gasket from the oil filler cap.





4. REMOVE SPARK PLUG





(a) Using a 14 mm spark plug wrench, remove the 4 spark plugs.

Text in Illustration





5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY





(a) Remove the 2 bolts, 2 O-rings and the 2 camshaft timing oil control valves.

6. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR





(a) Remove the 2 bolts and the 2 No. 1 crankshaft position sensors.

7. REMOVE VENTILATION VALVE SUB-ASSEMBLY





(a) Using a 27 mm deep socket wrench, remove the ventilation valve.

8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY





(a) Remove the 17 bolts, 2 seal washers and the cylinder head cover.

Text in Illustration





NOTICE:
Be careful not to drop any of the gaskets into the engine when removing the cylinder head cover because the gaskets may stick to the cylinder head cover.

(b) Remove the cylinder head cover gasket.





9. REMOVE CAMSHAFT BEARING CAP OIL HOLE GASKET

(a) Remove the 2 camshaft bearing cap oil hole gaskets from the camshaft bearing cap.





10. REMOVE CRANKSHAFT POSITION SENSOR





(a) Remove the bolt and the crankshaft position sensor.

11. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY





(a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch.

12. REMOVE KNOCK SENSOR





(a) Remove the bolt and sensor.

13. REMOVE ENGINE COOLANT TEMPERATURE SENSOR





(a) Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor.

(b) Remove the gasket from the engine coolant temperature sensor.

14. REMOVE OIL FILTER ELEMENT

(a) Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.





Text in Illustration





(b) Remove the oil filter drain plug.





(c) Install the pipe to the oil filter cap.





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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 as shown in the illustration.





(e) Remove the O-ring.

(f) Using SST, remove the oil filter cap.





SST : 09228-06501

(g) Remove the oil filter element and oil filter cap gasket from the oil filter cap.





Text in Illustration





NOTICE:
Be sure to remove the oil filter cap gasket by hand, without using any tools, to prevent damage to the groove.

15. REMOVE WATER PUMP PULLEY





(a) Using SST, remove the 4 bolts and water pump pulley.

SST : 09960-10010

09962-01000

09963-00600

16. SET NO. 1 CYLINDER TO TDC/COMPRESSION





(a) Turn the crankshaft pulley until its groove and the groove of the timing chain cover are aligned.

Text in Illustration





(b) Check that each timing mark of the camshaft timing gear and sprocket are located as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

17. REMOVE CRANKSHAFT PULLEY





(a) Using SST, remove the crankshaft pulley bolt.

SST : 09960-10010

09962-01000

09963-01000

(b) Remove the crankshaft pulley from the crankshaft.

18. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal

19. REMOVE TIGHT PLUG Removal

20. REMOVE WATER INLET HOUSING Removal

21. REMOVE WATER INLET Removal

22. REMOVE NO. 2 WATER INLET HOUSING GASKET Removal

23. REMOVE THERMOSTAT Removal

24. REMOVE TIMING CHAIN COVER OIL SEAL

(a) Using a screwdriver with its tip wrapped with protective tape, remove the timing chain cover oil seal.





Text in Illustration





NOTICE:
Do not damage the surface of the oil seal press fit hole.

25. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY





(a) Set the camshaft timing gear, camshaft timing exhaust gear and crankshaft in the positions (20° ATDC) shown in the illustration.

Text in Illustration





(b) Push down on the stopper plate to release the lock and push in the plunger.





Text in Illustration





(c) Pull up the stopper plate with the plunger pushed to the end and lock the plunger.





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(d) Insert a 3 mm (0.118 in.) diameter bar into the hole in the stopper plate and lock the plunger.





Text in Illustration





(e) Remove the 2 nuts and the No. 1 chain tensioner.





(f) Remove the chain tensioner gasket from the cylinder head.