Part 2

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY - (Continued)

28. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

(a) Remove the 15 bolts and 2 nuts as shown in the illustration.

(b) Remove the timing chain cover sub-assembly by prying between the timing chain cover and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver.

NOTICE:
Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.

HINT
Tape the screwdriver tip before use.

(c) Remove the 4 bolts, chain cover plate and chain cover plate gasket.

(d) Remove the gasket.

29. REMOVE TIMING CHAIN CASE OIL SEAL

(a) Using a screwdriver, pry out the timing chain case oil seal.

HINT
Tape the screwdriver tip before use.

30. SET NO. 1 CYLINDER TO TDC / COMPRESSION

(a) Temporarily tighten the pulley set bolt.

(b) Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC / compression).

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

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

(b) Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm diameter (0.05 in.) into the stopper plate's 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 CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft counterclockwise 10° to loosen the chain sub-assembly.

(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 the bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks.

(e) Remove the chain sub-assembly.

34. 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.

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 from the crankshaft.

(b) Remove the 2 keys from the crankshaft.

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

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

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

SST : 09922-10010

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

(c) Remove the 2 flange bolts and the 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.

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

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

(d) Remove the 5 camshaft bearing caps.

41. REMOVE CAMSHAFT

(a) Remove the camshaft.

42. REMOVE NO. 2 CAMSHAFT

(a) Remove the No. 2 camshaft.

43. 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.

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

HINT
Tape the screwdriver tip before use.

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

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

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

SST : 09922-10010

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

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

45. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

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

46. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

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

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

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

(d) Remove the 5 camshaft bearing caps.

47. REMOVE NO. 3 CAMSHAFT

(a) Remove the No. 3 camshaft.

48. REMOVE NO. 4 CAMSHAFT

(a) Remove the No. 4 camshaft.

49. 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.

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

HINT
Tape the screwdriver tip before use.

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

(a) Remove the 24 No. 1 valve rocker arm sub-assemblies.

HINT
Arrange the removed parts in the correct order.

51. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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

HINT
Arrange the removed parts in the correct order.

52. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

(a) Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
* Be careful not to drop washers into the cylinder head.
* Cylinder head warpage or cracking could result from removing bolts in an incorrect order.

HINT
Be sure to keep separate the removed parts for each installation position.

(b) Remove the cylinder head sub-assembly RH and cylinder head gasket.

53. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

(a) Uniformly loosen and remove the 2 cylinder head set bolts in several steps and in the sequence shown in the illustration.

(b) Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
* Be careful not to drop washers into the cylinder head.
* Cylinder head warpage or cracking could result from removing bolts in an incorrect order.

HINT
Be sure to keep separate the removed parts for each installation position.

(c) Remove the cylinder head sub-assembly LH and No. 2 cylinder head gasket.

54. REMOVE WATER INLET PIPE

(a) Remove 2 clamps and separate the No. 1 water by-pass hose.

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