Disassembly

2GR-FXE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

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

2. REMOVE SPARK PLUG Removal

3. REMOVE OIL PAN DRAIN PLUG

(a) Remove the oil pan drain plug and oil pan drain plug gasket.

4. REMOVE PCV VALVE SUB-ASSEMBLY Removal

5. REMOVE VVT SENSOR (for Bank 2) Removal

6. REMOVE VVT SENSOR (for Bank 1) Removal

7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2) Removal

8. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1) Removal

9. REMOVE CRANK POSITION SENSOR Removal

10. REMOVE NO. 1 OIL PIPE

(a) Remove the 2 oil pipe unions, 3 gaskets and No. 1 oil pipe.

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(b) Remove the oil control valve filter LH.

NOTICE:
Do not touch the mesh when removing the oil control valve filter.

11. REMOVE OIL PIPE

(a) Remove the bolt.

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(b) Remove the 2 oil pipe unions, 3 gaskets and oil pipe.

(c) Remove the oil control valve filter RH.

NOTICE:
Do not touch the mesh when removing the oil control valve filter.

12. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

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

(b) Remove the 2 cylinder block water drain cock plugs from the 2 water drain cock sub-assemblies.

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13. REMOVE OIL FILTER ELEMENT Replacement

14. REMOVE CRANKSHAFT PULLEY Removal

15. REMOVE OIL COOLER ASSEMBLY

(a) Remove the 2 nuts and clamp, disconnect the water pipe sub-assembly and remove the gasket.

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(b) Remove the bolt and 2 clamps, disconnect the No. 4 water by-pass hose and detach the hose clamp.

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16. REMOVE NO. 1 OIL COOLER BRACKET

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

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(b) Remove the bolt, 2 nuts, No. 1 oil cooler bracket and gasket.

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(a) Remove the engine oil level dipstick guide.

(b) Remove the O-ring.

18. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH

(a) Remove the 6 bolts and front No. 1 engine mounting bracket LH.

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(b) Using an E8 "TORX" socket wrench, remove the 2 stud bolts.

19. REMOVE WATER INLET HOUSING

(a) Remove the 2 nuts, water inlet and thermostat.

(b) Remove the gasket.

(c) Remove the 2 stud bolts.

(d) Separate the No. 1 water by-pass hose from the water inlet housing.

(e) Remove the air drain cock plug.

(f) Remove the air drain cock assembly.

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

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(h) Remove the 2 O-rings.

20. REMOVE WATER OUTLET

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

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

21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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

(b) Remove the 3 gaskets.

22. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

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

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NOTICE:
The baffle plate is located at the back of the part shown in the illustration. Do not damage the baffle plate when removing the cylinder head cover sub-assembly LH.

(b) Remove the 3 gaskets.

23. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 16 bolts and 2 nuts.

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(b) Insert the blade of an 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.

(c) Using an E6 "TORX" socket wrench, remove the 2 stud bolts.

24. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.

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(b) Using an E6 "TORX" socket wrench, remove the 2 stud bolts.

25. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 16 bolts and 2 nuts.

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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.

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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.

(d) Using an E8 "TORX" socket wrench, remove the 2 stud bolts.

26. REMOVE NO. 1 OIL PAN BAFFLE PLATE

(a) Remove the 7 bolts and No. 1 oil pan baffle plate.

27. REMOVE REAR ENGINE OIL SEAL RETAINER

(a) Remove the 6 bolts.

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

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

HINT
Tape the screwdriver tip before use.

28. REMOVE REAR ENGINE OIL SEAL

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

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

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

HINT
Tape the screwdriver tip before use.

29. REMOVE ENGINE WATER PUMP ASSEMBLY Removal

30. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal

31. REMOVE FRONT CRANKSHAFT OIL SEAL Removal

32. SET NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Temporarily install 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).

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(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.

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HINT
For the intake camshaft:

Be sure to check mark A at the point where marks B, C, and D are positioned in a line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

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

33. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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

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(b) Move the stopper plate downward to set the lock, and then insert a pin with a diameter of 1.27 mm (0.0500 in.) into the stopper plate hole.

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

34. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the chain tensioner slipper.

35. REMOVE CHAIN SUB-ASSEMBLY

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

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(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 position it as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks.

(e) Remove the chain sub-assembly.

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36. 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.

37. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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

38. REMOVE NO. 2 CHAIN VIBRATION DAMPER

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

39. REMOVE CRANKSHAFT TIMING SPROCKET

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

(b) Remove the 2 keys from the crankshaft.

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

41. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY Removal

42. REMOVE CAMSHAFT BEARING CAP (for Bank 1) 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 CAMSHAFT HOUSING SUB-ASSEMBLY LH Removal

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

49. REMOVE VALVE LASH ADJUSTER ASSEMBLY Removal

50. REMOVE VALVE STEM CAP Removal

51. REMOVE CYLINDER HEAD SUB-ASSEMBLY Removal

52. REMOVE CYLINDER HEAD GASKET

53. REMOVE CYLINDER HEAD LH Removal

54. REMOVE NO. 2 CYLINDER HEAD GASKET

55. REMOVE WATER INLET PIPE

(a) Remove the clamp and disconnect the No. 1 water by-pass hose.

(b) Remove the 2 bolts and water inlet pipe.