Part 1

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY
(a) Remove the oil filler cap sub-assembly and oil filler gasket.
2. REMOVE SPARK PLUG
(a) Remove the spark plugs.
3. REMOVE OIL PAN DRAIN PLUG

(a) Remove the oil pan drain plug and oil pan drain plug gasket.
4. REMOVE VENTILATION VALVE SUB-ASSEMBLY

(a) Remove the ventilation valve sub-assembly.
5. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the 4 bolts and 4 camshaft position sensors.
6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Remove the 4 bolts and 4 camshaft oil control valves.
7. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the bolt and crankshaft position sensor.
8. REMOVE NO. 1 OIL PIPE

(a) Remove the 2 oil pipe unions, gaskets and oil pipe.
(b) Remove the oil control valve filter LH and gaskets.
9. REMOVE OIL PIPE

(a) Remove the bolt.
(b) Remove the 2 oil pipe unions and oil pipe.
(c) Remove the oil control valve filter RH and gaskets.
10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Remove the cylinder block water drain cocks from the cylinder block.
(b) Remove the cylinder block water drain cock plugs from the water drain cocks.
11. REMOVE OIL FILTER ELEMENT

(a) Remove the drain plug.
NOTE: Do not remove the O-ring from the oil filter cap.

(b) Connect the hose to the pipe.
(c) Insert the pipe with the hose into the oil filter cap.
(d) Make sure that the oil is completely drained and remove the pipe and O-ring.

(e) Using SST, remove the oil filter cap sub-assembly.
SST: 09228-06501

(f) Remove the oil filter element and O-ring from the oil filter cap sub-assembly.
NOTE: Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.

12. REMOVE CRANKSHAFT PULLEY

(a) Using SST, loosen the crankshaft pulley bolt.
SST: 09213-70011
09213-70020
SST: 09330-00021

(b) Using SST, remove the crankshaft pulley bolt and crankshaft pulley.
SST: 09950-50013
09951-05010
09952-05010
09953-05020
09954-05021
13. REMOVE OIL COOLER ASSEMBLY

(a) Remove the bolt, 2 clamps, and 4 clips and disconnect the 2 water by-pass hoses.

(b) Remove the union bolt, oil cooler assembly, and O-ring.
14. REMOVE NO. 1 OIL COOLER BRACKET

(a) Remove the 3 bolts, 3 nuts, and oil cooler pipe with No. 1 oil cooler bracket.

(b) Remove the bolt, 2 nuts, No. 1 oil cooler bracket, and gasket.
(c) Using a "TORX" socket wrench E8, remove the 2 stud bolts.
15. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH

(a) Remove the 6 bolts and No. 1 front engine mounting bracket LH.
(b) Using a "TORX" socket wrench E8, remove the 2 stud bolts.
16. REMOVE WATER INLET HOUSING

(a) Remove the 2 nuts, water inlet and thermostat.
(b) Remove the gasket.
(c) Remove the drain cock plug.
(d) Remove the drain cock assembly.
(e) Remove the 2 stud bolts.
(f) Separate the No. 1 water by-pass hose.

(g) Remove the 2 bolts, nut, and water inlet housing.

(h) Remove the 2 O-rings.
17. REMOVE WATER OUTLET

(a) Remove the 2 bolts, 4 nuts and water outlet.

(b) Remove the 2 gaskets and O-ring.
18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)

(a) Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.

(b) Remove the 3 gaskets.
19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)

(a) Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.
NOTE: 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.
20. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 16 bolts and 2 nuts.

(b) Insert the oil pan seal cutter blade between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.
NOTE: Be careful not to damage the contact surfaces of the oil pans.

(c) Using a "TORX" socket wrench E6, remove the 2 stud bolts.
21. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.
(b) Using a "TORX" socket wrench E6, remove the 2 stud bolts.
22. REMOVE OIL PAN SUB-ASSEMBLY

(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 sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly with a screwdriver.
NOTE: 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.
(d) Using a "TORX" socket wrench E8, remove the 2 stud bolts.
23. REMOVE OIL PAN BAFFLE PLATE NO.1

(a) Remove the 7 bolts and oil pan baffle plate.
24. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 6 bolts.

(b) Using a screwdriver, pry out the engine rear oil seal retainer.
NOTE: Be careful not to damage the engine rear oil seal retainer.
HINT: Tape the screwdriver tip before use.

25. REMOVE ENGINE REAR OIL SEAL

(a) Place the oil seal retainer on wooden blocks.
NOTE: Be careful not to damage the engine rear oil seal retainer.

(b) Using a screwdriver and a hammer, tap out the oil seal.
HINT: Tape the screwdriver tip before use.

26. REMOVE WATER PUMP ASSEMBLY

(a) Remove the 16 bolts, water pump assembly and gasket.
27. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

(a) Remove the 15 bolts and 2 nuts as shown in the illustration.

(b) Remove the timing chain cover sub-assembly by prying between the timing chain cover and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver.
NOTE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.
HINT: Tape the screwdriver tip before use.

(c) Remove the 4 bolts, chain cover plate and chain cover plate gasket.

(d) Remove the gasket.
28. REMOVE TIMING CHAIN CASE OIL SEAL

(a) Using a screwdriver, pry out the timing chain case oil seal.
HINT: Tape the screwdriver tip before use.

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 those 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 pin of dia1.27 mm (0.05 in.) into the stopper plate's hole.

(c) Remove the 2 bolts and No. 1 chain tensioner assembly.
31. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the chain tensioner slipper.
32. REMOVE CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft counterclockwise 10° to loosen the chain sub-assembly of the crankshaft timing sprocket.
(b) Remove the pulley set bolt.

(d) Turn the camshaft timing gear assembly on the bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the banks.
(e) Remove the chain.
33. 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.
34. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and No. 1 chain vibration damper.
35. REMOVE NO. 2 CHAIN VIBRATION DAMPER
(a) Remove the 2 No. 2 chain vibration dampers.
36. REMOVE CRANKSHAFT TIMING SPROCKET

(a) Remove the crankshaft timing sprocket from the crankshaft.
(b) Remove the 2 keys from the crankshaft.
37. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

(a) While raising the No. 2 chain tensioner assembly, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix the No. 2 chain tensioner.

(b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.
- Be careful not to damage the cylinder head with the wrench.
- Do not disassemble the camshaft timing gear assemblies.

(c) Remove the No. 2 chain assembly.
38. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt and No. 2 chain tensioner assembly.
39. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

(a) Check that the camshafts are positioned as shown in the illustration.

(b) Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.

(c) Uniformly loosen and remove the 12 bearing cap bolts in the sequence shown in the illustration.
NOTE: Uniformly loosen the bolts while keeping the camshaft level.

(d) Remove the 5 bearing caps.