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

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

Remove the 2 water drain cocks from the cylinder block.

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

10. REMOVE OIL FILTER ELEMENT (for 2WD) 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 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

15. REMOVE WATER PUMP ASSEMBLY Removal

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

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

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

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

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

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

18. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY (for 2WD)

(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.

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

(c) Remove the drain plug and gasket.

19. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY (for 4WD)

(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) 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.

(c) Remove the drain plug and gasket.

20. REMOVE OIL STRAINER PIPE SUB-ASSEMBLY (for 4WD)

Remove the 3 nuts, pipe and gasket.

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

21. REMOVE OIL PAN SUB-ASSEMBLY (for 2WD)

(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.

22. REMOVE OIL PAN SUB-ASSEMBLY (for 4WD)

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.

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.

Remove the 2 O-rings.

23. REMOVE OIL STRAINER SUB-ASSEMBLY (for 2WD)

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

24. REMOVE OIL STRAINER SUB-ASSEMBLY (for 4WD)

(a) Remove the bolt, 2 nuts, strainer and gasket.

25. REMOVE NO. 1 OIL PAN BAFFLE PLATE (for 2WD)

(a) Remove the 8 bolts and baffle plate.

26. REMOVE NO. 1 OIL PAN BAFFLE PLATE (for 4WD)

(a) Remove the 7 bolts and baffle plate.

27. 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.

28. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (w/ Oil Pump) Removal

29. 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.

30. 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.

31. REMOVE CHAIN TENSIONER SLIPPER

32. 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.

33. 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.

34. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and vibration damper.

35. REMOVE NO. 2 CHAIN VIBRATION DAMPER

(a) Remove the 2 chain vibration dampers.

36. REMOVE CRANKSHAFT TIMING SPROCKET

(a) Remove the crankshaft timing sprocket from the crankshaft.

(b) Remove the 2 set keys from the crankshaft.

37. 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.

38. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt and chain tensioner.

39. 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 camshaft and No. 2 camshaft.