Disassembly

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

DISASSEMBLY
HINT:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets, O-rings and oil seals with new parts.

1. REMOVE ENGINE HANGERS
(a) Remove the 2 bolts and engine hanger No. 1.
(b) Remove the 2 bolts and engine hanger No. 2.
2. REMOVE OIL LEVEL GAGE GUIDE
(a) Remove the bolt, then pull out the oil level gauge guide.
(b) Remove the O-ring from the oil level gauge guide.
3. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Remove the 2 water drain cocks.

4. REMOVE VVT SENSOR
(a) Remove the 2 bolts, then remove the 2 VVT sensors.

5. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the bolt, then remove the crankshaft position sensor.

6. REMOVE OIL CONTROL VALVE FILTER
(a) Remove the plug and filter, then remove the gasket from each cylinder head.

7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove the 10 bolts, 3 seal washers and 2 nuts, then remove the cylinder head cover.
(b) Remove the gasket from the cylinder head cover.

8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Remove the 10 bolts, 3 seal washers and 2 nuts, then remove the cylinder head cover.
(b) Remove the gasket from the cylinder head cover.
(c) Remove the ventilation valve from the cylinder head cover.
9. REMOVE CRANKSHAFT PULLEY

(a) Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned.

(b) Check that each timing mark of the camshaft timing gears is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.

(d) Using the pulley set bolt and SST, remove the crankshaft pulley.
SST: 09950-50013
09951-05010
09952-05010
09953-05020
09954-05031
10. REMOVE OIL PAN DRAIN PLUG
(a) Remove the drain plug and gasket.
11. REMOVE NO.2 OIL PAN SUB-ASSEMBLY

(a) Remove the 15 bolts and 2 nuts (for 2WD).

(b) Remove the 10 bolts and 2 nuts (for Pre Runner and 4WD).

(c) Insert the blade of the oil pan seal cutter between the oil pan and oil pan No. 2, then cut off applied sealer and remove the oil pan No. 2.

NOTE:
- Be careful not to damage the contact surface of the oil pan and oil pan No. 2.
- Be careful not to damage the oil pan No. 2 flange.

12. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the 2 nuts, then remove the oil strainer and gasket (for 2WD).

(b) Remove the 2 nuts, then remove the oil strainer and gasket (for Pre Runner and 4WD).
13. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 17 bolts and 2 nuts (for 2WD).

(b) Remove the 17 bolts and 2 nuts (for Pre Runner and 4WD).

(c) Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block in the sequence shown.
NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

(d) Remove the O-ring from the oil pump.

14. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 17 bolts, then remove the water pump and gasket.
15. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

(a) Remove the 15 bolts and 2 nuts.

(b) Remove the timing chain cover by prying between the timing chain cover, cylinder head and cylinder block with a screwdriver.
NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head.

(c) Remove the O-ring from the LH cylinder head.
16. REMOVE NO.1 CHAIN TENSIONER ASSEMBLY
NOTICE:
- Never rotate the crankshaft with the chain tensioner removed.
- When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.

(a) While turning the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration.
(b) While turning the stopper plate of the tensioner downward, insert a bar of dia 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate.
(c) Remove the 2 bolts, then remove the chain tensioner.
17. REMOVE CHAIN TENSIONER SLIPPER

18. REMOVE IDLE SPROCKET ASSEMBLY
(a) Using a 10 mm hexagon wrench, remove the idle gear shaft No. 2, idle gear No. 1 and idle gear shaft No. 1.

19. REMOVE NO.2 CHAIN VIBRATION DAMPER
(a) Remove the 2 chain vibration dampers No. 2.
20. REMOVE CHAIN SUB-ASSEMBLY
21. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

22. REMOVE NO.1 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts, then remove the chain vibration damper No. 1.
23. REMOVE CAMSHAFT TIMING GEARS AND NO.2 CHAIN (for Bank 1)

(a) While raising the chain tensioner No. 2 upward, insert a pin of dia 1.0 mm (0.039 in.) into the hole to fix it.

(b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and timing chain No. 2.

NOTE:
- Be careful not to damage the cylinder head and valve lifter with the wrench.
- Do not disassemble the camshaft timing gear assembly.

24. REMOVE NO.2 CHAIN TENSIONER ASSEMBLY
(a) Remove the bolt, then remove the chain tensioner No. 2.
25. REMOVE CAMSHAFT TIMING GEARS AND NO.2 CHAIN (for Bank 2)

(a) While pushing down the chain tensioner No. 3, insert a pin of dia 1.0 mm (0.039 in.) into the hole to fix it.

26. REMOVE NO.3 CHAIN TENSIONER ASSEMBLY
(a) Remove the bolt, then remove the chain tensioner No. 3.
27. REMOVE CAMSHAFTS
NOTICE: Keep the camshaft level while it is being removed. The camshaft thrust clearance is very small and failing to keep it level could crack or damage the cylinder head journal surface, which receives the thrust. This could subsequently lead the camshaft to seize or break. Perform the following steps to avoid such problems.

(a) Remove the camshafts of the RH bank.

(1) Rotate the camshafts counterclockwise using a wrench so that cam lobes of No. 1 cylinder face in the directions as shown in the illustration.

(2) Using several steps, uniformly loosen and remove the 16 bearing cap bolts in the sequence shown in the illustration.
(3) Remove the 8 bearing caps, then remove the 2 camshafts.

(b) Remove the camshafts of the LH bank.
(1) Using several steps, uniformly loosen and remove the 16 bearing cap bolts in the sequence shown in the illustration.
(2) Remove the 8 bearing caps, then remove the 2 camshafts.
28. REMOVE NO.1 CAMSHAFT BEARING
29. REMOVE NO.2 CAMSHAFT BEARING
30. REMOVE CYLINDER HEADS

(a) Using several steps, remove the 2 cylinder head bolts on the LH cylinder head in the sequence shown in the illustration.

(b) Using several steps, loosen the 8 cylinder head bolts on each cylinder head with a 10 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 16 cylinder head bolts, then remove the plate washers.

NOTE:
- Be careful not to drop the plate washers into the cylinder head.
- Cylinder head warpage or cracking could result from removing the bolts in the wrong order.

(c) Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench.
NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
HINT: If the cylinder head is difficult to remove, pry between the cylinder head and cylinder block with a screwdriver.

(d) Remove the RH and LH cylinder head gaskets.

31. REMOVE NO.1 WATER OUTLET PIPE
(a) Separate the knock sensor wire.
(b) Remove the 3 bolts, then remove the water outlet pipe.

32. REMOVE KNOCK CONTROL SENSOR
(a) Disconnect the knock sensor connectors.
(b) Remove the 2 bolts, then remove the 2 knock sensors.

33. REMOVE REAR ENGINE OIL SEAL RETAINER
(a) Remove the 5 bolts and 2 nuts.
(b) Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and crankshaft bearing cap.

34. REMOVE VALVE LIFTER
HINT: Arrange the valve lifter in the correct order.

35. REMOVE VALVE
HINT: Arrange the valves, inner compression springs, valve spring retainers and valve spring retainer rocks in the correct order.

(a) Place the cylinder head on a wooden block.
(b) Using SST, compress the inner compression spring and remove the 2 valve spring retainer rocks.
SST: 09202-70020
09202-00010
(c) Remove the valve, inner compression spring and valve spring retainer.

36. REMOVE VALVE SPRING SEAT
(a) Using compressed air and a magnetic finger, remove the valve spring seat by blowing air.

37. REMOVE VALVE STEM OIL O SEAL OR RING
(a) Using needle-nose pliers, remove the valve stem oil seal.
38. CLEAN CYLINDER HEAD SUB-ASSEMBLY

(a) Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.
NOTICE: Be careful not to scratch the cylinder block contact surface.

(b) Using a wire brush, remove all the carbon from the combustion chambers.
NOTICE: Be careful not to scratch the combustion chambers.

(d) Using a soft brush and solvent, thoroughly clean the cylinder head.

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

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

40. REMOVE CONNECTING ROD BEARING

41. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression rings.
(b) Remove the 2 side rails and oil ring by hand.

42. REMOVE HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
43. REMOVE WITH PISTON SUB-ASSEMBLY

(a) Gradually heat the piston to approximately 80°C (176°F).

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

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

44. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.04 to 0.24 mm (0.0016 to 0.0094 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum, replace the pair of the thrust washers or crankshaft.
HINT: Thrust washer thickness:
1.93 to 1.98 mm (0.0760 to 0.0780 in.)

45. REMOVE CRANKSHAFT

(a) Using several steps, uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the sequence shown in the illustration.

(b) Using several steps, uniformly loosen and remove the 16 main bearing cap bolts in the sequence shown in the illustration.

(c) Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and lower bearings.

NOTE:
- Pull up the main bearing cap by turning it to the right and left little by little.
- Be careful not to damage the joint surfaces of the cylinder block and the main bearing cap.

46. REMOVE CRANKSHAFT THRUST WASHER SET
47. REMOVE CRANKSHAFT BEARING

48. REMOVE NO.1 SUB-ASSEMBLY OIL NOZZLE
(a) Using a 5 mm socket hexagon wrench, remove the 3 oil nozzles.