Disassembly

4GR-FSE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

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

2. REMOVE RADIATOR CAP SUB-ASSEMBLY

(a) Remove the radiator cap sub-assembly.

3. REMOVE SPARK PLUG Removal

4. REMOVE OIL PAN DRAIN PLUG

(a) Remove the drain plug and gasket.

5. REMOVE VENTILATION VALVE SUB-ASSEMBLY

(a) Remove the ventilation valve sub-assembly.

6. REMOVE VVT SENSOR

(a) Remove the 4 bolts and 4 sensors.

7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Remove the 4 bolts and 4 oil control valves.

8. REMOVE CRANK POSITION SENSOR

(a) Remove the bolt and crank position sensor.

9. REMOVE NO. 1 OIL PIPE

(a) Remove the oil check valve bolt, oil pipe union and No. 1 oil pipe.

Text in Illustration

(b) Remove the oil control valve filter LH and gaskets.

10. REMOVE NO. 2 OIL PIPE

(a) Remove the oil check valve bolt, oil pipe union and No. 2 oil pipe.

Text in Illustration

(b) Remove the oil control valve filter RH and gaskets.

11. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Remove the 2 cylinder block water drain cock assemblies from the cylinder block.

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

12. REMOVE OIL FILTER ELEMENT

(a) Using SST, remove the oil filter cap.

SST : 09228-06501

HINT
Place a container for oil to be drained before removing the cap.

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

Text in Illustration

NOTICE:
To prevent the O-ring groove from being damaged, do not use any tools when removing the O-ring.

13. REMOVE CRANKSHAFT PULLEY

(a) Using SST, loosen the crankshaft pulley bolt.

Text in Illustration

SST : 09213-70011

09213-70020

SST : 09330-00021

(b) Using SST, remove the crankshaft pulley bolt and crankshaft pulley.

Text in Illustration

SST : 09950-50013

09951-05010

09952-05010

09953-05020

09954-05021

14. REMOVE INLET WATER ASSEMBLY

(a) Separate the 3 water by-pass hoses.

(b) Remove the 4 bolts, nut and inlet water assembly.

(d) Remove the 3 water by-pass hoses.

15. REMOVE INLET WATER WITH THERMOSTAT SUB-ASSEMBLY

(a) Remove the 3 nuts and inlet water with thermostat sub-assembly.

(b) Remove the gasket from the inlet water.

16. REMOVE REAR WATER BY-PASS JOINT

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

(b) Remove the 2 gaskets and O-ring.

17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove the 14 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.

(b) Remove the 3 gaskets.

18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Remove the 12 bolts, seal washer, cylinder head cover sub-assembly LH and No. 2 cylinder head cover gasket.

Text in Illustration

NOTICE:
The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the head cover.

(b) Remove the 3 gaskets.

19. REMOVE SPARK PLUG TUBE GASKET LH

(a) Pry up the claws of the ventilation baffle plate.

Text in Illustration

NOTICE:
Do not deform the claws of the baffle plate more than necessary.

(b) Remove the 3 spark plug tube gaskets from the cylinder head cover sub-assembly.

NOTICE:
* As much as possible prevent the spark plug tube gaskets from being deformed. The removed gaskets will be used when reinstalling the gaskets.
* Do not damage the connection of the cylinder head cover.

20. REMOVE SPARK PLUG TUBE GASKET

HINT
Perform the same procedure as for the LH side.

21. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 15 bolts and 2 nuts.

Text in Illustration

(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 sub-assembly.

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

22. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 16 bolts and 2 nuts.

Text in Illustration

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.

HINT
Tape the screwdriver tip before use.

(c) Remove the 2 O-rings.

23. REMOVE OIL STRAINER SUB-ASSEMBLY

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

24. REMOVE NO. 1 OIL PAN BAFFLE PLATE

(a) Remove the 8 bolts and baffle plate.

25. REMOVE REAR ENGINE OIL SEAL RETAINER

(a) Remove the 6 bolts.

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

Text in Illustration

NOTICE:
Be careful not to damage the rear engine oil seal retainer.

HINT
Tape the screwdriver tip before use.

26. REMOVE REAR ENGINE OIL SEAL

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

Text in Illustration

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

NOTICE:
Be careful not to damage the rear engine oil seal retainer.

HINT
Tape the screwdriver tip before use.

27. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal

28. REMOVE WATER PUMP ASSEMBLY

(a) Remove the 7 bolts, water pump assembly and water pump gasket.

29. REMOVE TIMING CHAIN CASE OIL SEAL

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

Text in Illustration

HINT
Tape the screwdriver tip before use.

30. SET NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Temporarily tighten the pulley set bolt.

(b) Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression).

Text in Illustration

(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.

Text in Illustration

If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.

31. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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

Text in Illustration

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

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

32. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the chain tensioner slipper.

33. REMOVE CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket.

Text in Illustration

(b) Remove the pulley set bolt.

(c) Remove the chain sub-assembly from the crankshaft timing sprocket and place it on the crankshaft.

(d) Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks.

(e) Remove the chain sub-assembly.

34. REMOVE IDLE SPROCKET ASSEMBLY

(a) Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft.

35. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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

36. REMOVE NO. 2 CHAIN VIBRATION DAMPER

(a) Remove the 2 No. 2 chain vibration dampers.

37. REMOVE CRANKSHAFT TIMING SPROCKET

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

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

38. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) Removal

39. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY Removal

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

41. REMOVE CAMSHAFT Removal

42. REMOVE NO. 2 CAMSHAFT Removal

43. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH Removal

44. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) Removal

45. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY Removal

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

47. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY Removal

48. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY Removal

49. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH Removal

50. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Removal

51. REMOVE VALVE LASH ADJUSTER ASSEMBLY Removal

52. REMOVE CYLINDER HEAD SUB-ASSEMBLY Removal

53. REMOVE CYLINDER HEAD GASKET Removal

54. REMOVE CYLINDER HEAD LH Removal

55. REMOVE NO. 2 CYLINDER HEAD GASKET Removal

56. REMOVE KNOCK CONTROL SENSOR

(a) Disconnect the knock sensor wire.

(b) Disconnect the 2 knock sensor connectors.

(c) Remove the 2 bolts and knock sensors.

57. REMOVE CYLINDER BLOCK WATER JACKET SPACER RH

(a) Using needle-nose pliers, remove the cylinder block water jacket spacer RH.

NOTICE:
Be sure to remove the water jacket spacer if turning the cylinder block.

58. REMOVE CYLINDER BLOCK WATER JACKET SPACER LH

(a) Using needle-nose pliers, remove the cylinder block water jacket spacer LH.

NOTICE:
Be sure to remove the water jacket spacer if turning the cylinder block.

59. REMOVE OUTLET WATER PIPE SUB-ASSEMBLY

(a) Remove the 2 bolts and outlet water pipe sub-assembly.