Disassembly

3UR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

1. REMOVE OIL FILTER ELEMENT Replacement

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

3. REMOVE OIL FILTER BRACKET (w/ Oil Cooler) Removal

4. REMOVE OIL FILTER BRACKET (w/o Oil Cooler) Removal

5. REMOVE CRANKSHAFT PULLEY Removal

6. REMOVE OIL FILLER CAP SUB-ASSEMBLY

7. REMOVE OIL FILLER CAP HOUSING

Remove the 2 bolts, filler cap housing and gasket.

8. REMOVE SPARK PLUG

9. REMOVE VVT SENSOR

LH:

Remove the 2 bolts and 2 VVT sensors.

RH:

Remove the 2 bolts and 2 VVT sensors.

10. REMOVE CAMSHAFT POSITION SENSOR

Remove the bolt and camshaft position sensor.

11. REMOVE CRANK POSITION SENSOR PROTECTOR

(a) Remove the 2 bolts and sensor protector.

12. REMOVE CRANKSHAFT POSITION SENSOR

Remove the bolt and crankshaft position sensor.

13. REMOVE CAMSHAFT OIL CONTROL VALVE ASSEMBLY

LH:

Remove the 2 bolts and 2 oil control valves.

RH:

Remove the 2 bolts and 2 oil control valves.

14. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH Removal

15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH Removal

16. REMOVE OIL CONTROL VALVE FILTER

(a) LH:

Remove the 3 bolts, cylinder head cover spacer, gasket and valve filter.

RH:

Remove the 3 bolts, cylinder head cover spacer, gasket and valve filter.

17. REMOVE SPARK PLUG TUBE GASKET

(a) Bend the 4 ventilation baffle plate claws on the cylinder head cover to an angle of 90° or more.

(b) Using a screwdriver, pry out the gaskets.

NOTICE:
Be careful not to damage the cylinder head cover.

HINT
* Be careful not to damage the gasket when removing it, as the removed gasket needs to be used when installing a new one.
* Tape the screwdriver tip before use.

18. REMOVE WATER PUMP ASSEMBLY Removal

19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal

20. REMOVE WATER INLET PIPE Removal

21. REMOVE FRONT CRANKSHAFT OIL SEAL

(a) Place the timing chain cover on wooden blocks.

Place the oil pump on a wooden block.

(b) Using a screwdriver and wooden block, pry out the oil seal.

NOTICE:
Do not damage the surface of the oil seal press fit hole.

HINT
Tape the screwdriver tip before use.

22. SET NO. 1 CYLINDER TO TDC / COMPRESSION

(a) Temporarily tighten the pulley set bolt.

(b) Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

HINT
If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

23. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH

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

(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate hole.

Remove the 2 bolts, chain tensioner and gasket.

24. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

25. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH

(a) Remove the 2 bolts and chain vibration damper.

26. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH

(a) While pushing down the No. 3 chain tensioner, insert a pin of dia1.0 mm (0.0394 in.) into the hole to fix it in place.

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

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

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

NOTICE:
Be careful not to damage the cylinder head with the wrench.

(b) Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket LH.

(c) Remove the No. 1 and No. 2 chains from the gears.

27. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Remove the 2 bolts and chain tensioner.

28. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH

Remove the 2 bolts and chain tensioner.

29. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

30. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH

(a) Remove the 2 bolts and vibration damper.

31. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH

(a) While raising up the No. 2 chain tensioner, insert a pin of dia1.0 mm (0.0394 in.) into the hole to fix it in place.

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

NOTICE:
Be careful not to damage the cylinder head with the wrench.

(b) Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket RH.

(c) Remove the No. 1 and No. 2 chains from the gears.

32. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Remove the 2 bolts and chain tensioner.

33. REMOVE CRANKSHAFT TIMING GEAR KEY

(a) Using a screwdriver, remove the 2 timing gear keys from the crankshaft.

34. REMOVE CAMSHAFT BEARING CAP LH

(a) Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

NOTICE:
Uniformly loosen the bolts while keeping the camshaft level.

(b) Remove the 6 bearing caps.

HINT
Arrange the removed parts in the correct order.

(c) Remove the No. 3 and No. 4 camshafts.

35. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

NOTICE:
Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

HINT
Tape the screwdriver tip before use.

36. REMOVE CAMSHAFT BEARING CAP RH

(a) Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

NOTICE:
Uniformly loosen the bolts while keeping the camshaft level.

(b) Remove the 6 bearing caps.

HINT
Arrange the removed parts in the correct order.

(c) Remove the No. 1 and No. 2 camshafts.

37. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

(a) Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

NOTICE:
Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

HINT
Tape the screwdriver tip before use.

38. REMOVE VALVE ROCKER ARM SUB-ASSEMBLY

(a) Remove the 32 valve rocker arms from the cylinder head.

HINT
Arrange the removed parts in the correct order.

39. REMOVE VALVE LASH ADJUSTER ASSEMBLY

(a) Remove the 32 valve lash adjusters from the cylinder head.

HINT
Arrange the removed parts in the correct order.

40. REMOVE VALVE STEM CAP

(a) Remove the 32 valve stem caps from the cylinder head.

HINT
Arrange the removed parts in the correct order.

41. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH Removal

42. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH Removal

43. REMOVE CYLINDER HEAD GASKET LH

44. REMOVE CYLINDER HEAD GASKET RH

45. REMOVE CYLINDER BLOCK WATER JACKET SPACER

(a) Remove the 2 water jacket spacers from the cylinder head.

NOTICE:
Be sure to remove the water jacket spacers. If not, they may fall and become damaged when the cylinder block is inverted.

46. REMOVE OIL RETURN PIPE GASKET

Using a screwdriver, pry out the oil return pipe gasket.

HINT
Tape the screwdriver tip before use.

47. REMOVE VENTILATION PIPE GASKET

Using a screwdriver, pry out the ventilation pipe gasket.

HINT
Tape the screwdriver tip before use.

48. REMOVE NO. 1 HEAT EXCHANGER COVER

Remove the 12 bolts and 2 nuts.

Remove the heat exchanger by prying between the heat exchanger and cylinder block with a screwdriver.

HINT
Tape the screwdriver tip before use.

49. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

Remove the 14 bolts and 2 nuts.

Insert the blade of oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

NOTICE:
Be careful not to damage the contact surfaces of the oil pans.

50. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY

Remove the 14 bolts and 2 nuts.

HINT
Be sure to clean the bolts and stud bolts, and check the threads for cracks or other damage.

Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.

NOTICE:
Be careful not to damage the contact surfaces of the cylinder block and oil pan.

HINT
Tape the screwdriver tip before use.

51. REMOVE NO. 1 OIL PAN BAFFLE PLATE

Remove the 7 bolts and baffle plate.

52. REMOVE OIL STRAINER SUB-ASSEMBLY

Remove the 2 bolts, oil strainer and O-ring.

53. REMOVE ENGINE REAR OIL SEAL RETAINER

Remove the 6 bolts and oil seal retainer.

Using a screwdriver, pry out the oil seal retainer.

HINT
Tape the screwdriver tip before use.

54. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY

Remove the bolt and oil drain pipe.

(a) Remove the O-ring.

55. REMOVE REAR CRANKSHAFT OIL SEAL

Place the oil seal retainer on wooden blocks.

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

56. REMOVE RING PIN

NOTICE:
It is not necessary to remove the ring pin unless it is being replaced.

57. REMOVE STUD BOLT

NOTICE:
If the stud bolt is deformed or its threads are damaged, replace it.