Part 2

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

33. REMOVE NO. 2 CHAIN VIBRATION DAMPER
(a) Remove the 2 No. 2 chain vibration dampers.
34. REMOVE CHAIN SUB-ASSEMBLY
35. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

36. REMOVE NO. 1 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts, then remove the No. 1 chain vibration damper.
37. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

(a) While raising chain tensioner No. 2 upward, 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 No. 2 timing chain.

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

38. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Remove the bolt, then remove the No. 2 chain tensioner.
39. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

(a) While pushing down the No. 3 chain tensioner, insert a pin of dia 1.0 mm (0.039 in.) into the hole to fix it.

40. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Remove the bolt, then remove the No. 3 chain tensioner.

41. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance:
0.04 to 0.09 mm (0.016 to 0.035 in.)
Maximum thrust clearance:
0.11 mm (0.0043 in.)
If the thrust clearance is greater than the maximum, replace the camshafts.
If necessary, replace the camshaft bearing caps and cylinder head as a set.
42. REMOVE CAMSHAFTS
NOTE: 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 force. This could subsequently lead the camshaft to seize or break. Perform the following steps to avoid such problems.

(a) Remove the camshafts of bank 1.

(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 bank 2.
(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.
43. REMOVE NO. 1 CAMSHAFT BEARING
(a) Remove the No. 1 camshaft bearing from the No. 1 camshaft bearing cap.

44. REMOVE NO. 2 CAMSHAFT BEARING
(a) Remove the No. 2 camshaft bearing from the cylinder head for bank 1.
45. INSPECT CAMSHAFT OIL CLEARANCE

(a) Clean the camshaft bearing caps, camshaft bearings and camshaft journals.
(b) Install the camshaft bearing.
(c) Place the camshaft on the cylinder head.
(d) Lay a strip of Plastigage across each camshaft journal.
(e) Install the camshaft bearing caps.
NOTE: Do not turn the camshafts.

(f) Remove the camshaft bearing caps.

(g) Measure the Plastigage at its widest point.
Standard oil clearance (Bank 1):

Standard oil clearance (Bank 2):

Maximum oil clearance (Bank 1):

Maximum oil clearance (Bank 2):
0.10 mm (0.0039 in.)
If the oil clearance is greater than the maximum, replace the camshaft bearings and/or camshafts.
If necessary, replace the camshaft bearing caps and cylinder head together.

(h) Remove the Plastigage completely.
(i) Remove the camshafts.
(j) Remove the camshaft bearing.
46. REMOVE CYLINDER HEADS

(a) 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.

(b) Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench.
NOTE: 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.

(c) Remove the bank 1 and bank 2 cylinder head gaskets.

47. REMOVE NO. 1 WATER OUTLET PIPE
(a) Separate the knock sensor wire.
(b) Remove the 3 bolts, then remove the water outlet pipe.

48. REMOVE KNOCK SENSOR
(a) Disconnect the 2 knock sensor connectors.
(b) Remove the 2 bolts, then remove the 2 knock sensors.

49. 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.

50. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance:
0.15 to 0.30 mm (0.0059 to 0.0118 in.)
Maximum thrust clearance:
0.35 mm (0.0138 in.)
51. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check the matchmarks on the connecting rod and cap are aligned to ensure correct assembly.

(b) Remove the 2 connecting rod cap bolts.
(c) Clean the crank pin, bearing and connecting rod.
(d) Check the crank pin and bearing for any pits and scratches.

(e) Lay a strip of plastigage across the crank pin.

(f) Check that the protrusion of the connecting rod cap is facing in the correct direction.
(g) Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

(h) Tighten the bolts alternately to the specified torque.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)

(i) Mark the front side of the each connecting cap bolt with paint.
(j) Retighten the cap bolts 90° as shown in the illustration.
NOTE: Do not turn the crankshaft.

(k) Remove the 2 bolts, connecting rod cap and lower bearing.

(l) Measure the plastigage at its widest point.
Standard oil clearance:
0.026 to 0.046 mm (0.0010 to 0.0018 in.)
Maximum oil clearance:
0.066 mm (0.0025 in.)
NOTE: Completely remove the plastigage.

(m) When replacing the bearing, replace it with one with the same number as marked on the connecting rod. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4".
HINT: Standard bearing center wall thickness

(n) Remove the 2 connecting rod cap bolts.

52. REMOVE 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.

53. REMOVE CONNECTING ROD BEARING

54. 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.

55. REMOVE HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
56. 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.

57. 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.)

58. INSPECT CRANKSHAFT OIL CLEARANCE

(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.

(c) Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and lower bearings.

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.

(d) Lay a strip of plastigage across each journal.

(e) Examine the front marks and numbers, check the sequence order is as shown and install the bearing caps onto the cylinder block.
(f) Apply a light coat of engine oil to the threads of bearing cap bolts.
(g) Temporarily install the 8 main bearing cap bolts in the inside positions.

(h) Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block is under 6 mm (0.23 in.).

(i) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
(j) Apply a light coat of engine oil to the threads of main bearing cap bolts.

(k) Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.
Torque: 61 Nm (622 kgf-cm, 45 ft-lbf)

(l) Mark the front side of the bearing cap bolts with paint.
(m) Retighten the bearing cap bolts 90° in the sequence as shown.
(n) Check that the painted mark is now at a 90° angle from the front.
NOTE: Do not turn the crankshaft.

(o) Install the 8 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
(p) Remove the main bearing caps.

(q) Measure the Plastigage at its widest point.
Standard oil clearance:
0.018 to 0.030 mm (0.0007 to 0.0012 in.)
Maximum clearance:
0.046 mm (0.0018 in.)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.
NOTE: Completely remove the plastigage.

(r) Replace the bearing with the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 size of standard bearings, marked "1", "2", "3", "4" and "5".
Journal bearing:

HINT: EXAMPLE
Cylinder block "11" (A) + Crankshaft "06" (B)
=Total number 17 (Use bearing "3")

59. 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.

62. REMOVE NO. 1 SUB-ASSEMBLY OIL NOZZLE
(a) Using a 5 mm socket hexagon wrench, remove the 3 hexagon cap head blots and the 3 oil nozzles.
63. REMOVE OIL JET
64. REMOVE TIGHT PLUG
65. REMOVE STRAIGHT PIN
66. REMOVE STUD BOLT

67. DISASSEMBLY CYLINDER HEAD SUB-ASSEMBLY
Refer to the procedures up to "DISASSEMBLY CYLINDER HEAD" Disassembly.