Part 2

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY - Continued

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.

(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.

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

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.

NOTICE:
* 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.

(c) Using a valve guide bushing brush and solvent, clean all the valve guide bushes.

(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.

NOTICE:
* 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.