Part 2

2TR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (CONTINUED)

20. REMOVE CAMSHAFT
(a) Remove the camshaft sub-assembly.

21. REMOVE NO.2 CAMSHAFT
(a) Remove the No.2 camshaft sub-assembly.

22. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Remove the 16 valve rocker arm sub-assembly.

23. REMOVE CAMSHAFT TIMING SPROCKET
(a) Fix the camshaft with a vise and then remove the sprocket bolt and camshaft timing sprocket.

NOTE: Be careful not to damage the camshaft.

24. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

(a) Check the lock of the camshaft timing gear.
(1) Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked.

NOTE: Be careful not to damage the camshaft.

(b) Release the lock pin.
(1) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

HINT: 2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece.

(2) Break through the tape of the advance side path and the retard side path on the opposite side to the hole of the advance side path, as shown in the illustration.

(3) Apply approximately 200 kPa (2.0 kgf*cm2, 28 psi) of air pressure to the two broken paths.

CAUTION: Some oil splashing will occur. Cover the paths with a shop rag.

(4) Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path.
OK:
Gear rotates in the advance direction.

HINT: This operation releases the lock pin for the most retarded position.

(5) When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path, in that order.

NOTE: Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

(c) Check for smooth rotation.
(1) Rotate the camshaft timing gear within its movable range several times, but do not turn it to the most retarded position. Check that the gear rotates smoothly.
OK:
Gear rotates in the advance direction.

CAUTION: Do not use an air pressure to perform the smooth operation check.

(d) Check the lock in the most retarded position.
(1) Confirm that the camshaft timing gear is locked at the most retarded position.

25. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
(a) Remove the fringe bolt and camshaft timing gear.

NOTICE:
- Be sure not to remove the other 3 bolts.
- If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

26. REMOVE CYLINDER HEAD SUB-ASSEMBLY
(a) Uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 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.

(b) Remove the cylinder head.
27. REMOVE CYLINDER HEAD GASKET
(a) Remove the cylinder head and gasket.
28. REMOVE NO. 2 CHAIN VIBRATION DAMPER

(a) Move the stopper plate downward to release the lock, and push the plunger deep into the tensioner.
(b) Move the stopper plate upward to set the lock, and insert a hexagon wrench into the stopper plate's hole.

29. REMOVE NO. 3 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts and chain vibration damper No.3.

30. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Remove the hexagon wrench from the tensioner assembly No.2.
(b) Remove the nut and chain tensioner assembly No.2.

31. REMOVE NO.2 CHAIN SUB-ASSEMBLY
(a) Remove the bolt, balanceshaft drive gear shaft and balanceshaft drive gear.
(b) Remove the crankshaft timing sprocket No.2 and chain.

32. REMOVE NO. 4 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts and vibration damper No.4.

33. REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY
(a) Remove the 2 pulley set keys from the crankshaft.
34. REMOVE OIL FILTER SUB-ASSEMBLY

(a) Using SST, remove the oil filter.
SST: 09228-07501

(b) Using a 27 mm socket wrench, remove the oil filter union.
35. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY

(a) Remove the 2 bolts and nut from the oil filter bracket.
(b) Remove the 2 screw plugs and 2 gaskets from the oil filter bracket.

(d) Using a hexagon wrench, remove the oil filter bracket union.

36. REMOVE NO. 1 WITH HEAD TAPER SCREW PLUG
(a) Remove the taper screw plug from the cylinder block.

37. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver with its tip taped, pry out the oil seal retainer.

HINT: Tape the screwdriver tip before use.

38. REMOVE VALVE STEM CAP
(a) Remove the valve stem caps from the cylinder head.

HINT: Arrange the removed parts in the correct order.

39. REMOVE VALVE LASH ADJUSTER ASSEMBLY
(a) Remove the valve lash adjusters from the cylinder head.

HINT: Arrange the removed parts in the correct order.

40. REMOVE INTAKE VALVE

(a) Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.
SST: 09202-70020
09202-00010

(b) Remove the retainer, compression spring, and valve.

HINT: Arrange the removed parts in the correct order.

41. REMOVE EXHAUST VALVE

(a) Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.
SST: 09202-70020
09202-00010

(b) Remove the retainer, compression spring, and valve.

HINT: Arrange the removed parts in the correct order.

42. REMOVE VALVE STEM OIL SEAL
(a) Using needle-nose pliers, remove the oil seals.
43. REMOVE VALVE SPRING SEAT
(a) Remove the valve spring seats from the cylinder head.

44. REMOVE OIL CONTROL VALVE FILTER
(a) Using an 8 mm hexagon wrench, remove the screw plug.
(b) Remove the oil control valve filter and gasket.

45. REMOVE NO. 1 WITH HEAD STRAIGHT SCREW PLUG
(a) Using a 10 mm hexagon wrench, remove the 3 screw plugs and 3 gaskets.

NOTE: If water leaks from the w/ head straight screw plug No.1 or the plug corrodes, replace it.

46. REMOVE NO. 2 WITH HEAD STRAIGHT SCREW PLUG
(a) Using a 19 mm hexagon wrench, remove the screw plug and gasket.

NOTE: If water leaks from the w/ head straight screw plug No.2 or the plug corrodes, replace it.

47. REMOVE CRANKSHAFT BEARING

48. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

HINT:
- Keep the bearing, connecting rod and cap together.
- Arrange the piston and connecting rod assemblies in the correct order.

49. REMOVE CONNECTING ROD BEARING

HINT: Arrange the removed parts in the correct order.

50. REMOVE CRANKSHAFT

(a) Uniformly loosen the 10 bearing cap bolts, in several steps, in the sequence shown in the illustration.

HINT:
- Keep the lower bearings and crankshaft bearing caps together.
- Arrange the thrust washers in the correct order.

(b) Lift out the crankshaft.

(c) Remove the upper bearings and upper thrust washers from the cylinder block.

HINT: Arrange the main bearing caps, bearings and thrust washers in the correct order.

51. REMOVE CRANKSHAFT BEARING

HINT: Arrange the removed parts in the correct order.

52. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression rings.
(b) Using a piston ring expander, remove the oil ring rail.
(c) Remove the oil ring expander by hand.

HINT: Arrange the piston rings in the correct order.

53. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Remove the water drain cock sub-assembly from the cylinder block.
(b) Remove the water drain cock plug from the water drain cock sub-assembly.
54. REMOVE WITH PIN PISTON SUB-ASSEMBLY

(a) Check the fitting condition between the piston and piston pin.
(1) Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
(b) Disconnect the connecting rod from the piston.

(1) Using a screwdriver, pry off the snap rings from the piston.

(2) Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).

(3) Using a brass bar and plastic-faced hammer, lightly tap out the piston pin and remove the connecting rod.

- The piston and pin are a matched set.
- Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

55. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, remove the oil nozzles.
56. REMOVE NO.1 BALANCESHAFT

(a) Remove the bolt.

(b) Remove the balanceshaft from the cylinder block.

NOTE: When removing the balanceshaft, make sure to support the balanceshaft with both hands and avoid scratching the balanceshaft bearing on the cylinder block side.

57. REMOVE NO. 1 BALANCESHAFT DRIVEN GEAR
(a) Mount the head portion of the balanceshaft in a vise.

NOTE: Be careful not to damage the balanceshaft.

(b) Remove the bolt.
(c) Remove the balanceshaft driven gear No.1 (*1), sliding key (*2), balanceshaft thrust washer No.1 (*3) and balanceshaft thrust spacer (*4).
58. REMOVE NO.2 BALANCESHAFT

(a) Remove the 2 bolts.

59. REMOVE NO. 2 BALANCESHAFT DRIVEN GEAR
(a) Mount the head portion of the balanceshaft in a vise.

NOTE: Be careful not to damage the balanceshaft.

(b) Remove the bolt.
(c) Remove the balanceshaft driven gear No.2 (*1) and balanceshaft thrust washer No.2 (*2).