Part 1

2GR-FE 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 VENTILATION VALVE SUB-ASSEMBLY

(a) Remove the ventilation valve sub-assembly.





5. REMOVE VVT SENSOR

Removal

6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

Removal

7. REMOVE CRANKSHAFT POSITION SENSOR Removal

8. REMOVE NO. 1 OIL PIPE

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





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(b) Remove the oil control valve filter LH and gaskets.

9. REMOVE OIL PIPE

(a) Remove the bolt.





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(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





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(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.

11. REMOVE OIL FILTER ELEMENT Replacement

12. REMOVE CRANKSHAFT PULLEY Removal

13. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler)

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





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(b) Remove the union bolt, oil cooler assembly, and O-ring.





14. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)

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





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





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

15. REMOVE ENGINE OIL DIPSTICK GUIDE (w/ Oil Cooler)

(a) Remove the engine oil dipstick guide.





(b) Remove the O-ring.





16. REMOVE ENGINE OIL DIPSTICK GUIDE (w/o Oil Cooler)

(a) Remove the bolt and engine oil dipstick guide.





(b) Remove the O-ring.





17. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH

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





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

18. 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 drain cock plug.





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(f) Remove the drain cock assembly.

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

(h) Remove the 2 O-rings.





19. 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.





20. 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.





21. 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 on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the cylinder head cover sub-assembly LH.

(b) Remove the 3 gaskets.





22. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 16 bolts and 2 nuts.





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(b) Insert the blade of the 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.

23. 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.

24. 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 4 stud bolts.