Part 2

2GR-FSE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

40. 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.

41. 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.

42. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt and chain tensioner.

43. REMOVE CAMSHAFT (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.

44. 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.

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

(a) Remove the 24 valve rocker arms.

HINT
Arrange the removed parts in the correct order.

46. REMOVE VALVE LASH ADJUSTER ASSEMBLY

(a) Remove the 24 valve lash adjusters from the cylinder head.

HINT
Arrange the removed parts in the correct order.

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

(a) Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
* Be careful not to drop washers into the cylinder head.
* Head warpage or cracking could result from removing bolts in an incorrect order.

HINT
Be sure to keep the removed parts separate for each installation position.

(b) Remove the cylinder head and gasket.

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

(a) Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

(b) Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
* Be careful not to drop washers into the cylinder head.
* Head warpage or cracking could result from removing bolts in an incorrect order.

HINT
Be sure to keep the removed parts separate for each installation position.

(c) Remove the cylinder head and gasket.

49. REMOVE WATER OUTLET PIPE SUB-ASSEMBLY

(a) Remove the 2 bolts and outlet pipe.

50. REMOVE VALVE STEM CAP

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

HINT
Arrange the removed parts in the correct order.

51. REMOVE INTAKE VALVE

(a) Using SST and wooden blocks, compress the compression spring and remove the valve retainer lock.

SST : 09202-70020

09202-00010

(b) Remove the retainer, compression spring and valve.

HINT
Arrange the removed parts in the correct order.

52. REMOVE EXHAUST VALVE

(a) Using SST and wooden blocks, compress the compression spring and remove the valve retainer lock.

SST : 09202-70020

09202-00010

(b) Remove the retainer, compression spring and valve.

HINT
Arrange the removed parts in the correct order.

53. REMOVE VALVE STEM OIL SEAL

(a) Using needle-nose pliers, remove the oil seals.

54. REMOVE VALVE SPRING SEAT

(a) Using compressed air and a magnetic finger, remove the valve spring seat by blowing air onto it.

55. REMOVE NO. 1 STRAIGHT SCREW PLUG

NOTICE:
If water leaks from the No. 1 screw plug or the plug is corroded, replace it.

(a) Using a 10 mm hexagon wrench, remove the 4 screw plugs and 4 gaskets.

56. REMOVE NO. 2 STRAIGHT SCREW PLUG

(a) Using a 14 mm hexagon wrench, remove the 2 screw plugs and 2 gaskets.

NOTICE:
If water leaks from the No. 2 screw plug or the plug is corroded, replace it.

57. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the bolt and crankshaft position sensor.

58. INSPECT CONNECTING ROD THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

Standard thrust clearance:

0.15 to 0.40 mm (0.0059 to 0.0157 in.)

Maximum thrust clearance:

0.50 mm (0.0197 in.)

If the thrust clearance is greater than the maximum, replace one or more connecting rods as necessary. If necessary, replace the crankshaft.

59. INSPECT CONNECTING ROD OIL CLEARANCE

(a) Check that the front mark on the connecting rod and cap are aligned to ensure the correct reassembly.

(b) Remove the 2 connecting rod cap bolts.

(c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

HINT
Keep the lower bearing inserted to the connecting rod cap.

(d) Clean the crank pin and bearing.

(e) Check the crank pin and bearing for pitting and scratches.

(f) Lay a strip of Plastigauge on the crank pin.

(g) Check that the front mark of the connecting rod cap is facing forward.

(h) Install and alternately tighten the bolts of the connecting rod cap in several steps.

Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)

NOTICE:
Do not turn the crankshaft.

(i) Mark the front side of each connecting cap bolt with paint.

(j) Retighten the cap bolts by 90° as shown.

(k) Check that the painted marks are now at a 90° angle to the front.

NOTICE:
Do not turn the crankshaft.

(l) Remove the 2 connecting rod cap bolts.

(m) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

HINT
Keep the lower bearing inserted to the connecting rod cap.

(n) Measure the Plastigauge at its widest point.

Standard oil clearance:

0.045 to 0.067 mm (0.0018 to 0.0026 in.)

Maximum oil clearance:

0.070 mm (0.0028 in.)

If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

HINT
If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, 3 or 4 mark on its surface.

Reference:

Connecting rod big end inside diameter
Standard sized bearing center wall thickness

Crankshaft pin diameter:

52.992 to 53.000 mm (2.0863 to 2.0866 in.)

(o) Completely remove the Plastigauge.

60. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD

(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.

(b) Push the piston, connecting rod and upper bearing through the top of the cylinder block.

HINT
* Keep the bearing, connecting rod and cap together.
* Arrange the piston and connecting rod in the correct order.

61. REMOVE CONNECTING ROD BEARING

HINT
Arrange the removed parts in the correct order.

62. INSPECT CRANKSHAFT THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

Standard thrust clearance:

0.04 to 0.24 mm (0.0016 to 0.0094 in.)

Maximum thrust clearance:

0.30 mm (0.0118 in.)

If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.

Standard thrust washer thickness:

2.43 to 2.48 mm (0.0957 to 0.0976 in.)

63. INSPECT CRANKSHAFT AND CRANKSHAFT OIL CLEARANCE

(a) Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in several steps, in the sequence shown in the illustration.

(b) Uniformly loosen the 16 bearing cap bolts in several steps, in the sequence shown in the illustration.

NOTICE:
* Pry up the main cap little by little to the right and left in turns.
* Be careful not to damage the joint surface of the cylinder block and main bearing caps.

(d) Clean each main journal and bearing.

(e) Check each main journal and bearing for pitting and scratches.

HINT
If the journal or bearing is damaged, replace the bearing.

(f) Place the crankshaft on the cylinder block.

(g) Lay a strip of Plastigauge across each journal.

(h) Examine the front marks and numbers and install the bearing caps on the cylinder block.

HINT
A number is marked on each main bearing cap to indicate the installation position.

(i) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

(j) Place the crankshaft bearing cap on the cylinder block.

(k) Install the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.

Bolt length:

100 to 102 mm (3.94 to 4.02 in.)

(l) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.

(m) Apply a light coat of engine oil on the threads and under the heads of the 8 main bearing cap bolts.

(n) Install the 8 main bearing cap bolts to the outside positions.

Bolt length:

HINT
The main bearing cap bolts are tightened in 2 progressive steps.

(o) Step 1:

(1) Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.

Torque : 61 Nm (622 kgf-cm, 45 ft-lbf)

HINT
If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.

NOTICE:
Do not turn the crankshaft.

(p) Step 2:

(1) Mark the front of the bearing cap bolts with paint.

(2) Retighten the bearing cap bolts by 90° in the order shown in step 1.

(3) Check that the painted marks are now at a 90° angle to the front.

(q) Install and uniformly tighten the 8 main bearing cap bolts in several steps, in the sequence shown in the illustration.

Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)

Bolt length:

(r) Remove the 24 bolts and bearing cap bolts.

(s) Completely remove the Plastigauge.

(t) If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft. Refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

Journal bearing:

EXAMPLE:

Cylinder block "11" + Crankshaft "06" = Total number 17 (Use bearing "3")

Standard crankshaft main journal diameter:

Standard upper bearing center wall thickness (No. 1 and No. 4 journal):

Standard upper bearing center wall thickness (No. 2 and No. 3 journal):

Standard lower bearing center wall thickness (No. 1 and No. 4 journal):

Standard lower bearing center wall thickness (No. 2 and No. 3 journal):

(u) Lift out the crankshaft.

(v) Remove the upper bearings and upper thrust washers from the cylinder block.

HINT
Arrange the bearings and thrust washers in the correct order.

64. 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.

65. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, remove the 3 oil nozzles and bolts.

(b) Check the oil nozzles for damage or clogging.

If necessary, replace the oil nozzle.

66. REMOVE PISTON RING SET

HINT
Arrange the piston rings in the correct order.

(a) Using a piston ring expander, remove the 2 compression rings.

(b) Using a piston ring expander, remove the 2 oil ring rails.

(c) Remove the oil ring expander by hand.

67. REMOVE PISTON WITH PIN SUB-ASSEMBLY

(a) Check the fitting condition between the piston and piston pin.

(1) Try to move the piston back and forth on the piston pin.

HINT
If any movement is felt, replace the piston and pin as a set.

(b) Disconnect the connecting rod from the piston.

(1) Using a screwdriver, pry off the snap rings from the piston.

(2) Gradually heat the piston to approximately 80°C (176°F).

(3) Using a brass bar and plastic-faced hammer, lightly tap out the piston pin and remove the connecting rod.

HINT
* The piston and pin are a matched set.
* Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

(c) Clean piston.

(1) Using a gasket scraper, remove the carbon from the piston top.

(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.

(3) Using solvent and a brush, thoroughly clean the piston.

NOTICE:
Do not use a wire brush.