Disassembly

2UR-FSE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

HINT
When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side.

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

2. REMOVE OIL FILLER CAP HOUSING

(a) Remove the 2 bolts, 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 oil control valve.

(a) Remove the O-ring from the valve.

(b) for Bank 2:

Remove the bolt and oil control valve.

(b) Remove the O-ring from the valve.

8. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

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

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

9. REMOVE CAMSHAFT TIMING CONTROL MOTOR LH [1][2]Removal

10. REMOVE CAMSHAFT TIMING CONTROL MOTOR RH [1][2]Removal

11. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Remove the bolt and wire harness clamp bracket.

12. REMOVE OIL FILTER ELEMENT Replacement

13. REMOVE OIL FILTER BRACKET [1][2]Removal

14. REMOVE WATER PUMP PULLEY Removal

15. REMOVE FRONT WATER BY-PASS JOINT

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

16. REMOVE SPARK PLUG TUBE GASKET

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

HINT
Tape the screwdriver tip before use.

17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Remove the fuel pump spacer.

(b) Remove the fuel pump spacer gasket.

(c) Remove the 15 bolts in the order shown in the illustration. Then remove the 2 seal washers, cylinder head cover and gasket.

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

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

18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH

(a) Remove the fuel pump spacer.

19. REMOVE OIL CONTROL VALVE FILTER

(a) for LH:

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

(b) for RH:

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

20. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY [1][2]Removal

21. REMOVE CRANKSHAFT PULLEY [1][2]Removal

22. REMOVE WATER PUMP Removal

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

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

25. REMOVE FRONT CRANKSHAFT OIL SEAL

(a) Place the timing chain cover on wooden blocks.

(b) Using a screwdriver and wooden block, pry out the oil seal.

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

HINT
Tape the screwdriver tip before use.

26. SET NO. 1 CYLINDER TO TDC / COMPRESSION

(a) Temporarily install the crankshaft pulley 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.

(c) Remove the crankshaft pulley bolt.

27. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH

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

(b) Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

28. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

29. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH

Remove the 2 bolts and chain vibration damper.

30. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH

(a) While pushing down the No. 3 chain tensioner, insert a pin of dia1.0 mm (0.0394 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.
* 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, camshaft timing exhaust gear and crankshaft timing sprocket LH.

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

31. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Remove the 2 bolts and chain tensioner.

32. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH

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

(b) Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

33. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

34. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH

(a) Remove the 2 bolts and vibration damper.

35. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH

(a) While raising up the No. 2 chain tensioner, insert a pin of dia1.0 mm (0.0394 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, camshaft timing exhaust gear and crankshaft timing sprocket RH.

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

36. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Remove the 2 bolts and chain tensioner.

37. REMOVE CRANKSHAFT TIMING GEAR KEY

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

38. REMOVE CAMSHAFT BEARING CAP LH [1][2]Camshaft (For Bank 1)

39. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH [1][2]Camshaft (For Bank 1)

40. REMOVE CAMSHAFT BEARING CAP RH Camshaft (For Bank 2)

41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH Camshaft (For Bank 2)

42. 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.

43. 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.

44. REMOVE VALVE STEM CAP

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

HINT
Arrange the removed parts in the correct order.

45. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH Removal

46. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH Removal

47. REMOVE CYLINDER BLOCK WATER JACKET SPACER

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

NOTICE:
Be sure to remove the water jacket spacers. If not, they may fall and become damaged when the cylinder block is inverted.

48. REMOVE NO. 1 HEAT EXCHANGER COVER

(a) Remove the 12 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.

49. REMOVE VENTILATION PIPE GASKET

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

HINT
Tape the screwdriver tip before use.

50. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 13 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.

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

51. REMOVE NO. 1 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 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.

52. REMOVE NO. 1 OIL PAN BAFFLE PLATE

(a) Remove the 4 bolts and baffle plate.

53. REMOVE NO. 2 OIL PAN BAFFLE PLATE

(a) Remove the 4 bolts and baffle plate.

54. REMOVE ENGINE OIL LEVEL SENSOR Removal

55. REMOVE OIL STRAINER SUB-ASSEMBLY

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

56. 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.

57. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY

(a) Remove the bolt and oil drain pipe.

(b) Remove the O-ring.

58. REMOVE REAR CRANKSHAFT OIL SEAL

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

(b) Using a screwdriver and hammer, tap out the oil seal.

59. REMOVE STRAIGHT PIN

NOTICE:
It is not necessary to remove the straight pins unless they are being replaced.

60. REMOVE STUD BOLT

NOTICE:
If the stud bolts are deformed or their threads are damaged, replace them.