Part 1

2GR-FSE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

2. REMOVE SPARK PLUG

3. REMOVE RADIATOR CAP SUB-ASSEMBLY

(a) Remove the radiator cap.

4. REMOVE VENTILATION VALVE SUB-ASSEMBLY

(a) Remove the ventilation valve.

5. REMOVE VVT SENSOR

(a) Remove the 4 bolts and 4 sensors.

6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Remove the 4 bolts and 4 oil control valves.

7. 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.

8. 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.

9. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Remove the 2 water drain cocks from the cylinder block.

(b) Remove the water drain cock plugs from the water drain cocks.

10. REMOVE OIL FILTER ELEMENT Replacement

11. REMOVE WATER INLET

(a) Separate the water by-pass hoses.

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

(d) Remove the 3 water by-pass hoses.

12. 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.

13. 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.

14. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)

(a) Remove the 14 bolts, cylinder head cover and gasket.

HINT
Make sure the removed parts are returned to the same places they were remove a from.

15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)

(a) Remove the 12 bolts, cylinder head cover and gasket.

HINT
Make sure the removed parts are returned to the same places they were remove a from.

16. 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.

17. REMOVE OIL STRAINER SUB-ASSEMBLY

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

18. 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.

19. REMOVE OIL PAN BAFFLE PLATE NO.1

(a) Remove the 8 bolts and baffle plate.

20. REMOVE CRANKSHAFT PULLEY

(a) Using SST, loosen the crankshaft pulley set bolt.

SST : 09213-70011

09213-70020

SST : 09330-00021

(b) Using the pulley set bolt and SST, remove the crankshaft pulley.

SST : 09950-50013

09951-05010

09952-05010

09953-05020

09954-05021

21. REMOVE WATER PUMP ASSEMBLY Removal

22. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 6 bolts.

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

HINT
Tape the screwdriver tip before use.

23. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (W/ Oil Pump) [1][2]Removal

24. 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.

25. 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 hole.

(c) Remove the 2 bolts and chain tensioner.

26. REMOVE CHAIN TENSIONER SLIPPER

27. REMOVE NO. 1 CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing gear.

(b) Remove the chain from the crankshaft timing gear and place it on the crankshaft.

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

(d) Remove the chain.

28. 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.

29. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and vibration damper.

30. REMOVE NO. 2 CHAIN VIBRATION DAMPER

(a) Remove the 2 chain vibration dampers.

31. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

(a) Remove the pulley set bolt.

(b) Remove the crankshaft timing gear from the crankshaft.

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

32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 1)

(a) While raising up the No. 2 chain tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix it in place.

(b) Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly RH.

SST : 09922-10010

NOTICE:
* Be careful not to damage the cylinder head with SST.
* Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.
(c) Remove the No. 2 chain.

33. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt and chain tensioner.

34. REMOVE CAMSHAFT (for Bank 1)

(a) Remove the 3 gaskets.

(b) Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

(d) Uniformly loosen and remove the 14 bearing cap bolts in the sequence shown in the illustration.

NOTICE:
Uniformly loosen the bolts while keeping the camshaft level.

(e) Remove the 6 bearing caps.

(f) Remove the No. 1 and No. 2 camshafts.

35. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 1)

(a) Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

NOTICE:
Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

HINT
Tape the screwdriver tip before use.

36. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 2)

(a) While pushing down the chain tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix it in place.

(b) Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.

SST : 09922-10010

NOTICE:
* Be careful not to damage the cylinder head with SST.
* Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.
(c) Remove the No. 2 chain.

37. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt and chain tensioner.

38. REMOVE CAMSHAFT SUB-ASSEMBLY (for Bank 2)

(a) Remove the 3 gaskets.

(b) Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

(d) Uniformly loosen and remove the 13 bearing cap bolts in the sequence shown in the illustration.

NOTICE:
Uniformly loosen the bolts while keeping the camshaft level.

(e) Remove the 5 bearing caps.

(f) Remove the No. 3 and No. 4 camshafts.

39. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 2)

(a) Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

NOTICE:
Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

HINT
Tape the screwdriver tip before use.

40. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

(a) Remove the 24 valve rocker arms.

HINT
Arrange the removed parts in the correct order.