Disassembly

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

1. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Using a 24 mm deep socket wrench, remove the oil pressure switch.

2. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

(a) Using a 19 mm deep socket wrench, remove the sensor.

(b) Remove the gasket from the sensor.

3. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Remove the 2 water drain cock plugs from the water drain cocks.

(b) Remove the 2 water drain cocks from the cylinder block.

4. REMOVE VVT SENSOR

(a) LH:

Remove the 2 bolts and 2 VVT sensors.

(b) RH:

Remove the 2 bolts and 2 VVT sensors.

5. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the bolt and crankshaft position sensor.

6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH

(a) LH:

Remove the 2 bolts and 2 oil control valves.

(b) RH:

Remove the 2 bolts and 2 oil control valves.

7. REMOVE OIL FILLER CAP HOUSING

(a) Remove the oil filler cap.

(b) Remove the 2 nuts, oil filler cap housing and gasket.

8. REMOVE NO. 1 OIL PIPE Removal

9. REMOVE NO. 2 OIL PIPE Removal

10. REMOVE OIL FILTER ELEMENT Replacement

11. REMOVE OIL FILTER BRACKET Removal

12. REMOVE WATER INLET HOUSING Removal

13. REMOVE REAR WATER BY-PASS JOINT

(a) Remove the 2 bolts, 4 nuts, rear water by-pass joint and 2 gaskets.

(b) Remove the O-ring from the No. 1 water outlet pipe.

14. REMOVE SPARK PLUG Removal

15. REMOVE PCV VALVE SUB-ASSEMBLY

(a) Remove the PCV valve hose.

(b) Remove the PCV valve.

16. REMOVE CRANKSHAFT PULLEY Removal

17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

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

HINT
Make sure the removed parts are returned to the same places they were removed from.

(b) Remove the 3 gaskets.

18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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

HINT
Make sure the removed parts are returned to the same places they were removed from.

(b) Remove the 3 gaskets.

19. REMOVE SPARK PLUG TUBE GASKET

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

Text in Illustration

(b) Remove the 6 spark plug tube gaskets.

HINT
Be careful not to damage the gasket when removing it as the removed gasket needs to be used when installing a new one.

20. REMOVE OIL PAN DRAIN PLUG

(a) Remove the drain plug and gasket.

21. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY Removal

22. REMOVE OIL STRAINER SUB-ASSEMBLY Removal

23. REMOVE OIL PAN SUB-ASSEMBLY Removal

24. REMOVE NO. 1 OIL PAN BAFFLE PLATE

(a) Remove the 6 bolts and No. 1 oil pan baffle plate.

25. REMOVE ENGINE REAR 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.

Text in Illustration

HINT
Tape the screwdriver tip before use.

26. REMOVE REAR CRANKSHAFT OIL SEAL

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

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

27. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal

28. REMOVE WATER PUMP ASSEMBLY

(a) Remove the 8 bolts, water pump and gasket.

29. REMOVE FRONT CRANKSHAFT OIL SEAL Removal

30. 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).

Text in Illustration

(c) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration.

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

Text in Illustration

31. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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

Text in Illustration

(b) Move the stopper plate downward to set the lock, and insert a pin of dia1.27 mm (0.0500 in.) into the stopper plate hole.

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

32. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the chain tensioner slipper.

33. REMOVE NO. 1 CHAIN SUB-ASSEMBLY

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

Text in Illustration

(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° so that it is as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks.

(e) Remove the chain sub-assembly.

Text in Illustration

34. REMOVE NO. 1 IDLE GEAR SHAFT

(a) Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, No. 1 idle gear and No. 1 idle gear shaft.

35. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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

36. REMOVE NO. 2 CHAIN VIBRATION DAMPER

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

37. REMOVE CRANKSHAFT TIMING SPROCKET

(a) Remove the crankshaft timing sprocket.

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

(a) While raising the No. 2 chain tensioner assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to hold the No. 2 chain tensioner assembly.

Text in Illustration

(b) Using SST to hold the hexagonal portion of each camshaft, loosen the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

SST : 09922-10010

Text in Illustration

NOTICE:
Do not loosen the other 4 bolts. If any of the 4 bolts is loosened, replace the camshaft timing gear assembly and/or camshaft timing exhaust gear assembly with a new one.

(c) Remove the 2 bolts and camshaft timing gear assembly together with the No. 2 chain.

39. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt and No. 2 chain tensioner assembly.

40. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

(a) Check that the camshafts are positioned as shown in the illustration.

Text in Illustration

(b) Uniformly loosen and remove the 8 bearing cap bolts in several steps in the sequence shown in the illustration.

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

(d) Remove the 5 camshaft bearing caps.

(e) Remove the camshaft and No. 2 camshaft.

41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

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

Text in Illustration

HINT
Tape the screwdriver tip before use.

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

42. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

(a) While pushing down the No. 3 chain tensioner assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to hold the No. 3 chain tensioner assembly.

Text in Illustration

(b) Using SST to hold the hexagonal portion of each camshaft, loosen the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

SST : 09922-10010

Text in Illustration

NOTICE:
Do not loosen the other 4 bolts. If any of the 4 bolts is loosened, replace the camshaft timing gear assembly and/or camshaft timing exhaust gear assembly with a new one.

(c) Remove the 2 bolts and camshaft timing gear together with the No. 2 chain.

43. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt and No. 3 chain tensioner assembly.

44. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

(a) Check that the camshafts are positioned as shown in the illustration.

Text in Illustration

(b) Uniformly loosen and remove the 8 bearing cap bolts in several steps in the sequence shown in the illustration.

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

(d) Remove the 5 camshaft bearing caps.

(e) Remove the No. 3 camshaft and No. 4 camshaft.

45. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

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

Text in Illustration

HINT
Tape the screwdriver tip before use.

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

46. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

(a) Remove the 24 valve rocker arms from the cylinder head.

HINT
Arrange the removed parts in the correct order.

47. REMOVE VALVE LASH ADJUSTER ASSEMBLY

(a) Remove the 24 valve lash adjusters from the cylinder head.

HINT
Arrange the removed parts in the correct order.

48. REMOVE VALVE STEM CAP

(a) Remove the 24 valve stem caps from the cylinder head.

HINT
Arrange the removed parts in the correct order.

49. REMOVE CYLINDER HEAD SUB-ASSEMBLY Removal

50. REMOVE CYLINDER HEAD LH Removal

51. REMOVE CYLINDER HEAD GASKET

52. REMOVE NO. 2 CYLINDER HEAD GASKET

53. REMOVE NO. 1 WATER OUTLET PIPE Removal

54. REMOVE KNOCK SENSOR Removal

55. 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.

56. REMOVE STRAIGHT PIN

NOTICE:
It is not necessary to remove a straight pin unless it is being replaced.

57. REMOVE RING PIN

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

58. REMOVE STUD BOLT

NOTICE:
It is not necessary to remove a stud bolt unless it is being replaced.