Disassembly
2AR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY
1. REMOVE ENGINE COVER JOINT
(a) Remove the 3 joints.
2. REMOVE SPARK PLUG Removal
3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side) Removal
4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side) Removal
5. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side) Removal
6. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side) Removal
7. REMOVE OIL FILLER CAP SUB-ASSEMBLY
(a) Remove the oil filler cap from the cylinder head.
(b) Remove the gasket from the oil filler cap.
8. REMOVE CRANKSHAFT POSITION SENSOR Removal
9. REMOVE PCV VALVE Removal
10. REMOVE PCV CASE
(a) Remove the 8 bolts and 2 nuts.
(b) Remove the PCV case by prying between the PCV case and cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the cylinder block and PCV case.
HINT
Tape the screwdriver tip before use.
11. REMOVE SEPARATOR CASE
(a) Remove the 2 bolts, separator case and gasket.
12. REMOVE NO. 1 WATER BY-PASS PIPE
(a) Remove the bolt, 2 nuts, water by-pass pipe and gasket.
13. REMOVE WATER INLET Removal
14. REMOVE THERMOSTAT Removal
15. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Removal
16. REMOVE WATER PUMP ASSEMBLY Removal
17. REMOVE WATER INLET HOUSING
(a) Remove the 4 bolts, nut, water inlet housing and gasket.
18. REMOVE CRANKSHAFT PULLEY
(a) Using SST, hold the crankshaft pulley and loosen the pulley bolt until 2 or 3 threads are screwed into the crankshaft.
SST : 09213-54015
SST : 91551-80650
SST : 09330-00021
(b) Using SST and the pulley bolt, remove the crankshaft pulley.
SST : 09950-50013
09954-05011
09951-05010
09952-05010
09953-05020
Text in Illustration
HINT
Apply lubricant to the threads and end of SST.
19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Removal
20. REMOVE SPARK PLUG TUBE GASKET Removal
21. REMOVE ENGINE MOUNTING BRACKET RH Removal
22. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal
23. REMOVE TIMING CHAIN COVER TIGHT PLUG
(a) Using a 14 mm hexagon wrench, remove the plug and gasket.
24. REMOVE TIMING CHAIN COVER PLATE
(a) Remove the 4 bolts, timing chain cover plate and gasket.
25. REMOVE TIMING CHAIN COVER OIL SEAL Removal
26. SET NO. 1 CYLINDER TO TDC/COMPRESSION Removal
27. REMOVE TIMING CHAIN GUIDE Removal
28. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Removal
29. REMOVE CHAIN TENSIONER SLIPPER Removal
30. REMOVE CHAIN SUB-ASSEMBLY
31. REMOVE NO. 1 CHAIN VIBRATION DAMPER Removal
32. REMOVE CRANKSHAFT TIMING SPROCKET
(a) Remove the crankshaft timing sprocket from the crankshaft.
33. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY Removal
34. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Removal
35. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY Removal
36. REMOVE CAMSHAFT BEARING CAP Removal
37. REMOVE OIL CONTROL VALVE FILTER
(a) Remove the oil control valve filter from the No. 1 camshaft bearing cap.
38. REMOVE CAMSHAFT Removal
39. REMOVE NO. 1 CAMSHAFT BEARING
(a) Remove the No. 1 camshaft bearing.
40. REMOVE NO. 2 CAMSHAFT BEARING
(a) Remove the No. 2 camshaft bearing.
41. REMOVE CAMSHAFT HOUSING STUD BOLT
NOTICE:
If a stud bolt is deformed or its threads are damaged, replace it.
42. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN
NOTICE:
It is not necessary to remove the ring pin unless it is being replaced.
43. REMOVE CAMSHAFT HOUSING STRAIGHT PIN
NOTICE:
It is not necessary to remove the straight pin unless it is being replaced.
44. REMOVE VALVE ROCKER ARM SUB-ASSEMBLY Removal
45. REMOVE VALVE LASH ADJUSTER ASSEMBLY Removal
46. REMOVE VALVE STEM CAP Removal
47. REMOVE CYLINDER HEAD SUB-ASSEMBLY Removal
48. REMOVE CYLINDER HEAD GASKET Removal
49. REMOVE CYLINDER BLOCK WATER JACKET SPACER
(a) Remove the cylinder block water jacket spacer from the cylinder block.
NOTICE:
Be sure to remove the water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block is inverted.
50. REMOVE OIL FILTER ELEMENT Replacement
51. REMOVE OIL PAN SUB-ASSEMBLY
(a) Remove the 11 bolts and 2 nuts.
(b) Insert the blade of an oil pan seal cutter between the oil pan and stiffening crankcase, cut off the applied sealer and remove the oil pan.
NOTICE:
* Be careful not to damage the contact surfaces of the stiffening crankcase and oil pan.
* Be careful not to damage the stiffening crankcase flange.
52. REMOVE OIL STRAINER SUB-ASSEMBLY
(a) Remove the 3 bolts, oil strainer and gasket.
53. REMOVE NO. 1 OIL PAN BAFFLE PLATE
(a) Remove the 5 bolts and oil pan baffle plate.
54. INSPECT CRANKSHAFT BACKLASH
(a) Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.
Standard backlash:
0.005 to 0.020 mm (0.000197 to 0.000787 in.)
Maximum backlash:
0.020 mm (0.000787 in.)
If the backlash is more than the maximum, replace the engine balancer assembly.
55. REMOVE ENGINE BALANCER ASSEMBLY
(a) Remove the 7 bolts and engine balancer.
NOTICE:
Do not disassemble the engine balancer.
56. INSPECT BALANCE SHAFT THRUST CLEARANCE Engine Unit
57. REMOVE STIFFENING CRANKCASE ASSEMBLY
(a) Remove the 7 bolts.
(b) Using a screwdriver, remove the stiffening crankcase by prying between the stiffening crankcase and cylinder block at the places shown in the illustration.
Text in Illustration
HINT
Tape the screwdriver tip before use.
NOTICE:
Be careful not to damage the contact surfaces of the cylinder block and stiffening crankcase.
58. REMOVE STIFFENING CRANKCASE STUD BOLT
NOTICE:
If a stud bolt is deformed or its threads are damaged, replace it.
59. REMOVE STIFFENING CRANKCASE RING PIN
NOTICE:
It is not necessary to remove the ring pin unless it is being replaced.
60. REMOVE ENGINE REAR OIL SEAL
(a) Remove the engine rear oil seal from the cylinder block.
