Disassembly

1UR-FSE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

2. REMOVE OIL FILLER CAP HOUSING

(a) Remove the 2 bolts, oil filler cap housing and gasket.

3. REMOVE SPARK PLUG Removal

4. REMOVE VVT SENSOR

(a) for Bank 1:

Remove the 2 bolts and 2 VVT sensors.

(b) for Bank 2:

Remove the 2 bolts and 2 VVT sensors.

5. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the bolt and camshaft position sensor.

6. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the bolt and crankshaft position sensor.

7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) for Bank 1:

Remove the bolt and camshaft timing oil control valve assembly.

(b) for Bank 2:

Remove the bolt and camshaft timing oil control valve assembly.

8. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

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

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

9. REMOVE CAMSHAFT TIMING CONTROL MOTOR (for Bank 1) Removal

10. REMOVE CAMSHAFT TIMING CONTROL MOTOR (for Bank 2) Removal

11. REMOVE OIL FILTER ELEMENT Replacement

12. REMOVE OIL FILTER BRACKET

(a) Remove the 3 bolts, filter bracket and 2 gaskets.

13. REMOVE FRONT WATER BY-PASS JOINT

(a) Remove the 4 nuts, front water by-pass joint and 2 gaskets.

14. REMOVE SPARK PLUG TUBE GASKET

(a) Using a screwdriver, pry out the 8 spark plug tube gaskets.

HINT
Tape the screwdriver tip before use.

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

(a) Remove the fuel pump spacer gasket.

(b) Remove the 15 bolts, 2 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.

HINT
Make sure that the removed parts are returned to the original places they were removed from.

(c) Remove the 4 gaskets and 2 O-rings from the camshaft bearing caps (No. 2, No. 3, No. 7).

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

(a) Remove the fuel pump spacer gasket.

17. REMOVE OIL CONTROL VALVE FILTER

(a) for Bank 1:

(1) Remove the 2 bolts, cylinder head cover spacer, gasket and valve filter.

(b) for Bank 2:

(1) Remove the 2 bolts, cylinder head cover spacer, gasket and valve filter.

18. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

(a) Remove the standard bolt, 6 mm hexagon wrench bolt and belt tensioner.

19. REMOVE CRANKSHAFT PULLEY Removal

20. REMOVE WATER PUMP Removal

21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY [1][2]Removal

22. REMOVE INLET WATER PIPE [1][2]Removal

23. SET NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Temporarily tighten the pulley set bolt.

(b) Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

HINT
If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

24. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1)

(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.

25. REMOVE CHAIN TENSIONER SLIPPER (for Bank 1)

26. REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 1)

(a) Remove the 2 bolts and chain vibration damper.

27. REMOVE CHAIN SUB-ASSEMBLY (for Bank 1)

(a) While pushing down the No. 3 chain tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix it in place.

(b) Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt with a 12mm hexagon wrench.

NOTICE:
* Be careful not to damage the cylinder head with the wrench.
* Do not disassemble the camshaft timing gear.
(c) Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

NOTICE:
Be careful not to damage the cylinder head with the wrench.

(d) Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket.

(e) Remove the No. 1 and No. 2 chains from the gears.

28. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Remove the 2 bolts and chain tensioner.

29. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2)

(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.

30. REMOVE CHAIN TENSIONER SLIPPER (for Bank 2)

31. REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 2)

(a) Remove the 2 bolts and vibration damper.

32. REMOVE CHAIN SUB-ASSEMBLY (for Bank 2)

(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) Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt with a 12 mm hexagon wrench.

NOTICE:
Be careful not to damage the cylinder head with the wrench.

(d) Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket.

(e) Remove the No. 1 and No. 2 chains from the gears.

33. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Remove the 2 bolts and chain tensioner.

34. REMOVE CRANKSHAFT TIMING GEAR KEY

(a) Using a screwdriver, remove the 2 timing gear keys from the crankshaft.

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

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

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

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

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

(a) Remove the 32 valve rocker arms from the cylinder head.

HINT
Arrange the removed parts in the correct order.

40. REMOVE VALVE LASH ADJUSTER ASSEMBLY

(a) Remove the 32 valve lash adjusters from the cylinder head.

HINT
Arrange the removed parts in the correct order.

41. REMOVE VALVE STEM CAP

(a) Remove the 32 valve stem caps from the cylinder head.

HINT
Arrange the removed parts in the correct order.

42. REMOVE CYLINDER HEAD SUB-ASSEMBLY (for Bank 1) Removal

43. REMOVE CYLINDER HEAD SUB-ASSEMBLY (for Bank 2) Removal

44. REMOVE CYLINDER BLOCK WATER JACKET SPACER

(a) Remove the 2 cylinder block water jacket spacers from the cylinder head.

NOTICE:
Be sure to remove the cylinder block water jacket spacers. Otherwise, they may fall and become damaged when the cylinder block is inverted.

45. REMOVE OIL RETURN PIPE GASKET

(a) Using a screwdriver, pry out the oil return pipe gasket.

HINT
Tape the screwdriver tip before use.

46. REMOVE NO. 1 HEAT EXCHANGER COVER

(a) Remove the 11 bolts and 2 nuts.

(b) Remove the heat exchanger by prying between the heat exchanger and cylinder block with a screwdriver.

HINT
Tape the screwdriver tip before use.

47. REMOVE VENTILATION PIPE GASKET

(a) Using a screwdriver, pry out the ventilation pipe gasket.

HINT
Tape the screwdriver tip before use.

48. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 15 bolts and 2 nuts.

(b) Insert the blade of an oil pan 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.

49. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 14 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 sub-assembly 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 sub-assembly.

HINT
Tape the screwdriver tip before use.

50. REMOVE NO. 1 OIL PAN BAFFLE PLATE

(a) Remove the 8 bolts and No. 1 oil pan baffle plate.

51. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the 2 bolts, oil strainer sub-assembly and O-ring.

52. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 6 bolts.

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

HINT
Tape the screwdriver tip before use.

53. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY

(a) Remove the bolt and oil drain pipe sub-assembly.

(b) Remove the O-ring.

54. REMOVE NO. 1 VENTILATION CONNECTOR

(a) Remove the No. 1 ventilation connector.

HINT
When removing the No. 1 ventilation connector, the ventilation tube may separate from the No. 1 ventilation connector. If this occurs, be sure to remove it from the cylinder block.

If the ventilation tube comes off, check for deformation and damage. If normal, attach the ventilation tube to the No. 1 ventilation connector. If deformed or damaged, replace the No. 1 ventilation connector assembly.