Part 1

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

(a) Remove the oil filler cap sub-assembly and oil filler gasket.

2. REMOVE SPARK PLUG Removal

3. REMOVE OIL PAN DRAIN PLUG

(a) Remove the oil pan drain plug and oil pan drain plug gasket.

4. REMOVE VENTILATION VALVE SUB-ASSEMBLY

(a) Remove the ventilation valve sub-assembly.

5. REMOVE VVT SENSOR Removal

6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Removal

7. REMOVE CRANK POSITION SENSOR Removal

8. REMOVE NO. 1 OIL PIPE

(a) Remove the 2 oil pipe unions, gaskets and No. 1 oil pipe.

Text in Illustration

(b) Remove the oil control valve filter LH and gaskets.

9. REMOVE OIL PIPE

(a) Remove the bolt.

Text in Illustration

(b) Remove the 2 oil pipe unions and oil pipe.

(c) Remove the oil control valve filter RH and gaskets.

10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Remove the 2 cylinder block water drain cock sub-assemblies from the cylinder block.

(b) Remove the 2 cylinder block water drain cock plugs from the 2 water drain cock sub-assemblies.

11. REMOVE OIL FILTER ELEMENT

(a) Remove the drain plug.

NOTICE:
Do not remove the O-ring from the oil filter cap.

(b) Connect the hose to the pipe.

Text in Illustration

(c) Insert the pipe with the hose into the oil filter cap.

(d) Make sure that the oil is completely drained and remove the pipe and O-ring.

(e) Using SST, remove the oil filter cap sub-assembly.

SST : 09228-06501

(f) Remove the oil filter element and O-ring from the oil filter cap sub-assembly.

Text in Illustration

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

12. REMOVE CRANKSHAFT PULLEY Removal

13. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler)

(a) Remove the bolt, 2 clamps and 4 clips, and disconnect the 2 water by-pass hoses.

Text in Illustration

(b) Remove the union bolt, oil cooler assembly, and O-ring.

14. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)

(a) Remove the 3 bolts, 3 nuts, and oil cooler pipe with the No. 1 oil cooler bracket.

(b) Remove the bolt, 2 nuts, No. 1 oil cooler bracket, and gasket.

Text in Illustration

(c) Using an E8 "TORX" socket wrench, remove the 2 stud bolts.

15. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

(a) w/ oil cooler

(1) Remove the engine oil level dipstick guide.

(b) w/o oil cooler

(1) Remove the bolt and engine oil level dipstick guide.

16. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH

(a) Remove the 6 bolts and No. 1 front engine mounting bracket LH.

(b) Using an E8 "TORX" socket wrench, remove the 2 stud bolts.

17. REMOVE WATER INLET HOUSING

(a) Remove the 2 nuts, water inlet and thermostat.

(b) Remove the gasket.

(c) Remove the 2 stud bolts.

(d) Separate the No. 1 water by-pass hose from the water inlet housing.

(e) Remove the drain cock plug.

Text in Illustration

(f) Remove the drain cock assembly.

(g) Remove the 2 bolts, nut, and water inlet housing.

(h) Remove the 2 O-rings.

18. REMOVE WATER OUTLET

(a) Remove the 2 bolts, 4 nuts and water outlet.

Text in Illustration

(b) Remove the 2 gaskets and O-ring.

19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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

(b) Remove the 3 gaskets.

20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

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

(b) Remove the 3 gaskets.

21. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 16 bolts and 2 nuts.

Text in Illustration

(b) Insert the blade of the 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.

(c) Using an E6 "TORX" socket wrench, remove the 2 stud bolts.

22. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.

Text in Illustration

(b) Using an E6 "TORX" socket wrench, remove the 2 stud bolts.

23. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 16 bolts and 2 nuts.

Text in Illustration

HINT
Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

(b) Remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly with a screwdriver.

Text in Illustration

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.

(d) Using an E8 "TORX" socket wrench, remove the 2 stud bolts.

24. REMOVE NO. 1 OIL PAN BAFFLE PLATE

(a) Remove the 7 bolts and No. 1 oil pan baffle plate.