Part 2

2GR-FSE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (Continued)

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.

41. 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.

42. 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.

43. 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.

44. REMOVE WATER OUTLET PIPE SUB-ASSEMBLY

(a) Remove the 2 bolts and outlet pipe.

45. REMOVE VALVE STEM CAP

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

HINT
Arrange the removed parts in the correct order.

46. 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.

47. 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.

48. REMOVE VALVE STEM OIL SEAL

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

49. REMOVE VALVE SPRING SEAT

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

50. 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.

51. 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.

52. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the bolt and crankshaft position sensor.

53. 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.

54. 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 Plastigage 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.

NOTICE:
Do not turn the crankshaft.

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

(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 mark is 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 Plastigage 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 and 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 Plastigage.