Disassembly

2UR-GSE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

(a) Remove the oil filler cap sub-assembly.

(b) Remove the oil filler cap gasket from the oil filler cap.

2. REMOVE OIL FILLER CAP HOUSING

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





3. REMOVE SPARK PLUG Removal

4. REMOVE OIL PAN DRAIN PLUG

(a) Remove the oil pan drain plug and gasket from the No. 2 oil pan.

5. 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.





6. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the bolt and camshaft position sensor.





7. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the bolt and crankshaft position sensor.





8. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY LH

(a) Remove the bolt and camshaft timing oil control valve assembly LH.





(b) Remove the O-ring from the camshaft timing oil control valve assembly LH.

9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH

(a) Remove the bolt and camshaft timing oil control valve assembly RH.





(b) Remove the O-ring from the camshaft timing oil control valve assembly RH.

10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Remove the 2 cylinder block water drain cock plugs from the cylinder block water drain cock sub-assembly.





(b) Remove the 2 cylinder block water drain cock sub-assembly from the cylinder block.

11. REMOVE CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY LH (for Bank 1)

(a) Remove the 3 bolts and the camshaft timing control motor assembly LH.





(b) Remove the O-ring from the camshaft timing control motor assembly LH.

12. REMOVE CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY RH (for Bank 2)

(a) Remove the 3 bolts and the camshaft timing control motor assembly RH.





(b) Remove the O-ring from the camshaft timing control motor assembly RH.

13. REMOVE FRONT WATER BY-PASS JOINT

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





14. REMOVE OIL FILTER ELEMENT

(a) Using a SST, temporarily loosen the oil filter cap by approximately 4 turns.





SST : 09228-06501

HINT
Make sure that the oil filter cap ribs are vertical, this will allow the engine oil to drain from the gap between the oil filter cap and the housing.

(b) Remove the oil filter cap.

(c) Remove the oil filter element and O-ring from the oil filter cap.





NOTICE:
Be sure to remove the O-ring (for the cap) by hand, without using any tools, to prevent damage to the groove for the O-ring on the cap.

15. REMOVE OIL COOLER ASSEMBLY

(a) Remove the bolt.





(b) Remove the union bolt, gasket and oil cooler assembly.

16. REMOVE OIL FILTER BRACKET

(a) Remove the 2 bolts and oil filter bracket stay.





(b) Remove the 2 bolts, 2 nuts and oil filter bracket.





(c) Remove the 2 gaskets from the timing chain cover sub-assembly.

17. REMOVE CRANKSHAFT PULLEY Removal

18. REMOVE NO. 1 V-BANK COVER BRACKET (for Bank 1)

(a) Remove the No. 1 V-bank cover bracket from the cylinder head cover sub-assembly LH.





19. REMOVE NO. 1 V-BANK COVER BRACKET (for Bank 2)

(a) Remove the No. 1 V-bank cover bracket from the cylinder head cover sub-assembly.





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

(a) Remove the fuel pump spacer gasket.





(b) Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly LH and cylinder head cover gasket LH.

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

(c) Remove the 2 oil hole gaskets and 2 O-rings from the camshaft bearing caps.





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

(a) Remove the fuel pump spacer gasket.





(b) Remove the 16 bolts, 3 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 2 oil hole gaskets and 2 O-rings from the camshaft bearing caps.





22. REMOVE SPARK PLUG TUBE GASKET

(a) Using a screwdriver, pry out the 8 spark plug tube gaskets from the each cylinder head sub-assembly.





HINT
Tape the screwdriver tip before use.

23. REMOVE OIL CONTROL VALVE FILTER

(a) for Bank 1:

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





(b) for Bank 2:

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





24. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

(a) Remove the standard bolt, 6 mm hexagon bolt and V-ribbed belt tensioner assembly.





25. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal

26. REMOVE INLET WATER PIPE Removal

27. REMOVE WATER PUMP ASSEMBLY

(a) Remove the 5 bolts, water pump assembly and water pump gasket from the timing chain cover sub-assembly.





28. REMOVE NO. 1 OIL PIPE Removal

29. REMOVE NO. 2 OIL PIPE Removal

30. REMOVE NO. 3 OIL PIPE Removal

31. REMOVE SCAVENGING PUMP ASSEMBLY Removal

32. REMOVE TIMING CHAIN CASE OIL SEAL

(a) Using screwdriver, remove the timing chain case oil seal.





HINT
Tape the screwdriver tip before use.

33. SET NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Temporarily tighten the crankshaft 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.





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

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





(b) Move the stopper plate downward to set the lock, and insert a 2 mm hexagon wrench into the stopper plate hole.

(c) Remove the 2 bolts and chain tensioner.





(d) Remove the chain tensioner gasket.

35. REMOVE CHAIN TENSIONER SLIPPER (for Bank 1)

(a) Remove the chain tensioner slipper.





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

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





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

(a) While pushing down the No. 3 chain tensioner, insert a dia1.0 mm (0.0394 in.) pin 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 chain sub-assembly and No. 2 chain sub-assembly still connected to the gears, remove the camshaft timing gear assembly, camshaft timing exhaust gear and crankshaft timing sprocket LH.

(e) Remove the No. 1 chain sub-assembly and No. 2 chain sub-assembly from the gears.

38. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY (for Bank 1)

(a) Remove the 2 bolts and No. 3 chain tensioner assembly.





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

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





(b) Move the stopper plate downward to set the lock, and insert a 2 mm hexagon wrench into the stopper plate hole.

(c) Remove the 2 bolts and No. 1 chain tensioner assembly.





40. REMOVE CHAIN TENSIONER SLIPPER (for Bank 2)

(a) Remove the chain tensioner slipper.





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

(a) Remove the 2 bolts and No. 1 chain vibration damper.





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

(a) While raising up the No. 2 chain tensioner, insert a dia1.0 mm (0.0394 in.) pin 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 chain sub-assembly and No. 2 chain sub-assembly still connected to the gears, remove the camshaft timing gear assembly, camshaft timing exhaust gear and crankshaft timing gear.

(e) Remove the No. 1 chain sub-assembly and No. 2 chain sub-assembly from the gears.

43. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY (for Bank 2)

(a) Remove the 2 bolts and chain tensioner.





44. REMOVE CRANKSHAFT TIMING GEAR KEY

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





45. REMOVE OIL REFLECTOR PLATE LH (for Bank 1)

(a) Remove the 2 bolts and oil reflector plate LH from the cylinder head assembly LH.





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

47. REMOVE NO. 3 CAMSHAFT Removal

48. REMOVE NO. 4 CAMSHAFT Removal

49. REMOVE OIL REFLECTOR PLATE RH (for Bank 2)

(a) Remove the 2 bolts and oil reflector plate RH from the cylinder head assembly.





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

51. REMOVE CAMSHAFT Removal

52. REMOVE NO. 2 CAMSHAFT Removal

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

(a) Remove the 32 No. 1 valve rocker arms from the cylinder heads.





HINT
Arrange the removed parts in the correct order.

54. REMOVE VALVE ROCKER ARM PIVOT

(a) Remove the 32 valve rocker arm pivots from the cylinder head sub-assembly.

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

56. REMOVE NO. 2 CYLINDER HEAD GASKET (for Bank 1) Removal

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

58. REMOVE CYLINDER HEAD GASKET (for Bank 2) Removal

59. REMOVE CYLINDER BLOCK WATER JACKET SPACER

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





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

60. REMOVE HEAT EXCHANGER ASSEMBLY

(a) Remove the bolt.





(b) Remove the 11 bolts and 2 nuts.





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





HINT
Tape the screwdriver tip before use.

61. REMOVE VENTILATION PIPE GASKET

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





HINT
Tape the screwdriver tip before use.

62. 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.

63. 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.

64. REMOVE NO. 1 OIL PAN BAFFLE PLATE

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





65. REMOVE OIL STRAINER SUB-ASSEMBLY

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





66. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 6 bolts.





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





67. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY

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





(b) Remove the O-ring.