Part 2

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

38. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

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

39. 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 the sequence shown in the illustration.

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

(d) Remove the 5 bearing caps.

40. REMOVE CAMSHAFT

(a) Remove the camshaft.

41. REMOVE NO. 2 CAMSHAFT

(a) Remove the No. 2 camshaft.

42. 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.

HINT
Tape the screwdriver tip before use.

43. 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 dia1.0 mm (0.039 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 bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.

SST : 09922-10010

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

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

44. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

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

45. 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 the sequence shown in the illustration.

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

(d) Remove the 5 bearing caps.

46. REMOVE NO. 3 CAMSHAFT

(a) Remove the No. 3 camshaft.

47. REMOVE NO. 4 CAMSHAFT

(a) Remove the No. 4 camshaft.

48. 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.

HINT
Tape the screwdriver tip before use.

49. 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.

50. 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.

51. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

(a) 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.

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

52. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

(a) Uniformly loosen and remove the cylinder head set bolts 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.

53. 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.

54. REMOVE VALVE STEM CAP

(a) Remove the valve stem caps from the cylinder heads.

HINT
Arrange the removed parts in the correct order.

55. REMOVE INTAKE VALVE

(a) Using SST, compress the inner compression spring and remove the valve spring retainer locks.

SST : 09202-70020

09202-00010

(b) Remove the valve spring retainer, inner compression spring and intake valve.

HINT
Arrange the removed parts in the correct order.

56. REMOVE EXHAUST VALVE

(a) Using SST, compress the inner compression spring and remove the valve spring retainer locks.

SST : 09202-70020

09202-00010

(b) Remove the valve spring retainer, inner compression spring and exhaust valve.

HINT
Arrange the removed parts in the correct order.

57. REMOVE VALVE STEM OIL SEAL

(a) Using needle-nose pliers, remove the valve stem oil seals.

58. REMOVE VALVE SPRING SEAT

(a) Using compressed air and a magnetic finger, remove the valve spring seats by blowing air onto them.

59. REMOVE NO. 1 STRAIGHT SCREW PLUG

(a) Using a 10 mm hexagon wrench, remove the 4 No. 1 straight screw plugs and 4 gaskets.

NOTICE:
If water leaks from the straight screw plug or the plug corrodes, replace it.

60. REMOVE NO. 2 STRAIGHT SCREW PLUG

(a) Using a 14 mm hexagon wrench, remove the 2 No. 2 straight screw plugs and 2 gaskets.

NOTICE:
If water leaks from the straight screw plug or the plug corrodes, replace it.

61. REMOVE RING PIN

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

62. REMOVE STUD BOLT

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

63. REMOVE STRAIGHT PIN

NOTICE:
If the straight pin is deformed or the threads are damaged, replace it.

64. REMOVE INTAKE VALVE GUIDE BUSH

(a) Heat the cylinder head to 80 to 100°C (176 to 212°F).

(b) Place the cylinder head on wooden blocks.

(c) Using SST and a hammer, tap out the intake valve guide bushes.

SST : 09201-10000

09201-01050

SST : 09950-70010

09951-07100

65. REMOVE EXHAUST VALVE GUIDE BUSH

(a) Heat the cylinder head to 80 to 100°C (176 to 212°F).

(b) Place the cylinder head on wooden blocks.

(c) Using SST and a hammer, tap out the exhaust valve guide bushes.

SST : 09201-10000

09201-01050

SST : 09950-70010

09951-07100

66. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD

(a) Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned.

HINT
The matchmarks on the connecting rod sub-assembly and connecting rod cap are for ensuring the correct reassembly.

(b) Remove the 2 connecting rod cap bolts.

(c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

HINT
Keep the lower bearing inserted to the connecting rod cap.

(d) Using a ridge reamer, remove all the carbon from the top of the cylinder.

(e) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

HINT
* Keep the bearing, connecting rod and cap together.
* Arrange the piston and connecting rod assemblies in the correct order.
67. REMOVE CONNECTING ROD BEARING

HINT
Arrange the removed parts in the correct order.

68. REMOVE CRANKSHAFT

(a) Uniformly loosen and remove the 8 crankshaft bearing cap bolts and seal washers in several steps and in the sequence shown in the illustration.

(b) Uniformly loosen the 16 crankshaft bearing cap bolts, in several steps and in the sequence shown in the illustration.

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

NOTICE:
* Push up on the cap little by little, from the right and left side alternately so that the cap can be removed.
* Be careful not to damage the joint surface of the cylinder block and the main bearing cap.
(d) Remove the crankshaft.

69. REMOVE CRANKSHAFT BEARING

(a) Remove the upper crankshaft bearing and lower crankshaft bearing.

HINT
Arrange the removed parts in the correct order.

70. REMOVE CRANKSHAFT THRUST WASHER SET

(a) Remove the upper crankshaft bearings and upper crankshaft thrust washers from the cylinder block sub-assembly.

71. REMOVE PISTON RING SET

(a) Using a piston ring expander, remove the 2 compression rings.

(b) Remove the oil ring expander and 2 side rails by hand.

HINT
Arrange the removed parts in the correct order.

72. REMOVE PISTON SUB-ASSEMBLY WITH PIN

(a) Check the fitting condition between the piston and piston pin.

(1) Try to move the piston back and forth on the piston pin.

If any movement is felt, replace the piston and pin as a set.

(b) Disconnect the connecting rod from the piston.

(1) Using a screwdriver, pry off the piston pin hole snap rings from the piston.

(2) Gradually heat the piston to approximately 80°C (176°F).

(3) Using a brass bar and plastic hammer, 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.
(c) Using a gasket scraper, remove the carbon from the piston top.

(d) Using a groove cleaning tool or broken ring, clean the piston ring grooves.

(e) Using solvent and a brush, thoroughly clean the piston.

NOTICE:
Do not use a wire brush.

73. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, remove the bolts and No. 1 oil nozzle sub-assembly.

(b) Check the 3 oil nozzles for damage or clogging.

If necessary, replace the No. 1 oil nozzle sub-assembly.

74. CLEAN CYLINDER BLOCK