Disassembly

2GR-FSE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

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 Removal

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 VVT 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 crankshaft position sensor.

9. REMOVE NO. 1 OIL PIPE

(a) Remove the oil check valve bolt, oil pipe union and No. 1 oil pipe.

Text in Illustration

(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 No. 2 oil pipe.

Text in Illustration

(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

(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.

Text in Illustration

NOTICE:
Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.

13. 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

14. 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.

15. 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.

16. 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.

17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove the 14 bolts, head cover sub-assembly and gasket.

(b) Remove the 3 gaskets.

18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Remove the 12 bolts, head cover sub-assembly LH and gasket.

Text in Illustration

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.

(b) Remove the 3 gaskets.

19. 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.

20. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 15 bolts and 2 nuts.

(b) 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.

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

21. 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.

22. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the 3 nuts, oil strainer and gasket.

(b) Remove the 8 bolts and baffle plate.

23. 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.

24. REMOVE ENGINE REAR OIL SEAL

(a) Place the oil seal retainer on wooden blocks.

Text in Illustration

NOTICE:
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.

25. REMOVE WATER PUMP ASSEMBLY

(a) Remove the 16 bolts, water pump and gasket.

26. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

(a) Remove the 16 bolts and 2 nuts 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.

Text in Illustration

NOTICE:
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.

27. REMOVE TIMING CHAIN CASE OIL SEAL

(a) Using a screwdriver, pry out the oil seal.

Text in Illustration

HINT
Tape the screwdriver tip before use.

28. 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.

29. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

Text in Illustration

(b) Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm (0.0501 in.) diameter into the stopper plate's hole.

(c) Remove the 2 bolts and chain tensioner.

30. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the chain tensioner slipper.

31. 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.

(c) Remove the chain from the crankshaft timing sprocket and place it on the crankshaft.

(d) 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 between the banks.

(e) Remove the chain.

32. REMOVE IDLE SPROCKET ASSEMBLY

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

33. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and vibration damper.

34. REMOVE NO. 2 CHAIN VIBRATION DAMPER

(a) Remove the 2 vibration dampers.

35. REMOVE CRANKSHAFT TIMING SPROCKET

(a) Remove the crankshaft timing sprocket from the crankshaft.

(b) Remove the 2 pulley set keys from the crankshaft.

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

37. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY Removal

38. REMOVE CAMSHAFT BEARING CAP (for Bank 1) Removal

39. REMOVE CAMSHAFT Removal

40. REMOVE NO. 2 CAMSHAFT Removal

41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH Removal

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

43. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY Removal

44. REMOVE CAMSHAFT BEARING CAP (for Bank 2) Removal

45. REMOVE NO. 3 CAMSHAFT Removal

46. REMOVE NO. 4 CAMSHAFT Removal

47. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH Removal

48. REMOVE VALVE STEM CAP Removal

49. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Removal

50. REMOVE VALVE LASH ADJUSTER ASSEMBLY Removal

51. REMOVE CYLINDER HEAD SUB-ASSEMBLY Removal

52. REMOVE CYLINDER HEAD GASKET Removal

53. REMOVE CYLINDER HEAD LH Removal

54. REMOVE NO. 2 CYLINDER HEAD GASKET Removal

55. REMOVE KNOCK SENSOR

(a) Disconnect the knock sensor wire.

(b) Disconnect the 2 knock sensor connectors.

(c) Remove the 2 bolts and knock sensors.

56. REMOVE WATER OUTLET PIPE SUB-ASSEMBLY

(a) Remove the 2 bolts and water outlet pipe.