Part 1

PARTIAL ENGINE ASSEMBLY (2GR-FE)





























COMPONENTS

OVERHAUL
1. REMOVE OIL FILLER CAP SUB-ASSEMBLY
a. Remove the oil filler cap sub-assembly.
2. REMOVE SPARK PLUG





3. REMOVE OIL PAN DRAIN PLUG
a. Remove the drain plug and gasket.





4. REMOVE VENTILATION VALVE SUB-ASSEMBLY
a. Remove the ventilation valve sub-assembly.





5. REMOVE CAMSHAFT POSITION SENSOR
a. Remove the 4 bolts and 4 camshaft position sensors.





6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Remove the 4 bolts and 4 camshaft timing oil control valves.





7. REMOVE CRANK POSITION SENSOR
a. Remove the bolt and crank position sensor.





8. REMOVE OIL PIPE NO.1
a. Remove the 2 oil pipe unions and oil pipe No.1.
b. Remove the oil control valve filter LH and gaskets.





9. REMOVE OIL PIPE
a. Remove the bolt.
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
a. Remove the water drain cocks from the cylinder block.
b. Remove the water drain cock plugs from the water drain cocks.





11. REMOVE OIL FILTER ELEMENT
a. Remove the drain plug.

NOTICE: Do not remove the O-ring.





b. Connect the hose to the pipe.
c. Insert the pipe with the hose into the oil filter cap.
d. Make sure that the oil is completely drained and remove the pipe and O-ring.





e. Using SST, remove the oil filter cap.
SST 09228-06501





f. Remove the oil filter element and O-ring from the oil filter cap.

NOTICE: Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.

12. REMOVE CRANKSHAFT PULLEY





a. Using SST, loosen the crankshaft pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021





b. Using SST, remove the crankshaft pulley bolt and crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)





13. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH
a. Remove the 6 bolts, and engine mounting bracket front No.1 LH.
14. REMOVE WATER INLET HOUSING





a. Remove the 2 nuts, water inlet and thermostat.
b. Remove the gasket.
c. Remove the drain cock plug.
d. Remove the drain cock.





e. Remove the 2 bolts, nut, and water inlet housing.





f. Remove the 2 O-rings.
15. REMOVE WATER OUTLET





a. Remove the 2 bolts, 4 nuts, and water outlet.





b. Remove the 2 gaskets and O-ring.
16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH





a. Remove the 12 bolts, head cover and gasket.





b. Pry up the claws of the ventilation baffle plate.





c. Using a screwdriver with its tip taped and a hammer, tap out the 3 spark plug tube gaskets.
17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY





a. Remove the 12 bolts, head cover and gasket.





b. Pry up the claws of the ventilation baffle plate.





c. Using a screwdriver with its tip taped and a hammer, tap out the 3 spark plug tube gaskets.
18. REMOVE OIL PAN SUB-ASSEMBLY NO.2





a. Remove the 16 bolts and 2 nuts.





b. Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the oil pan sub-assembly No.2.
SST 09032-00100

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





19. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the bolt, 2 nuts, oil strainer and gasket.
20. REMOVE OIL PAN SUB-ASSEMBLY





a. Remove the 16 bolts and 2 nuts.

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





b. 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.





c. Remove the 2 O-rings.





21. REMOVE OIL PAN BAFFLE PLATE
a. Remove the 7 bolts and oil pan baffle plate.





22. REMOVE ENGINE REAR OIL SEAL
a. Remove the 6 bolts.





b. Using a screwdriver, pry out the oil seal retainer.

HINT: Tape the screwdriver tip before use.





c. Place the oil seal retainer on wooden blocks.
d. Using a screwdriver and a hammer, tap out the oil seal.

HINT: Tape the screwdriver tip before use.





23. REMOVE WATER PUMP ASSEMBLY
a. Remove the 16 bolts, water pump and gasket.
24. 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 by prying between the timing chain cover and cylinder head or cylinder block 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 gasket.





d. Remove the gasket.





25. REMOVE TIMING CHAIN COVER OIL SEAL
a. Using a screwdriver, pry out the oil seal.

HINT: Tape the screwdriver tip before use.

26. 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 the timing marks of the bearing cap as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.





27. REMOVE CHAIN TENSIONER ASSEMBLY NO.1
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's hole.
c. Remove the 2 bolts and chain tensioner.
28. REMOVE CHAIN TENSIONER SLIPPER
a. Remove the chain tensioner slipper.
29. REMOVE CHAIN SUB-ASSEMBLY





a. Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing gear.
b. Remove the chain from the crank timing gear and place it on the crankshaft.





c. Turn the camshaft timing gear assembly on the RH bank clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the center banks.
d. Remove the chain.





30. REMOVE IDLE SPROCKET ASSEMBLY
a. Using a 10 mm hexagon wrench, remove the idle gear shaft No.2, idle sprocket and idle gear shaft No.1.





31. REMOVE CHAIN VIBRATION DAMPER NO.1
a. Remove the 2 bolts and chain vibration damper No.1.
32. REMOVE CHAIN VIBRATION DAMPER NO.2
a. Remove the 2 chain vibration dampers.





33. REMOVE CRANKSHAFT TIMING GEAR
a. Remove the pulley set bolt.
b. Remove the crankshaft timing gear from the crankshaft.
c. Remove the 2 pulley set keys from the crankshaft.

34. REMOVE CAMSHAFT TIMING GEARS AND NO.2 CHAIN (RH BANK)





a. While raising up the chain tensioner No.2, insert a pin of diameter 1.0 mm (0.039 inch) into the hole to fix it.





b. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gears.

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

c. Remove the No.2 chain.





35. REMOVE CHAIN TENSIONER ASSEMBLY NO.2
a. Remove the bolt and chain tensioner No.2.
36. REMOVE CAMSHAFT BEARING CAP





a. Remove the 3 gaskets.





b. Make sure that the knock pin of the camshaft is positioned as shown in the illustration.





c. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.





d. Uniformly loosen and remove the 12 bearing cap bolts in the sequence shown in the illustration.

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

e. Remove the 5 bearing caps.