Part 1

2TR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

(a) Remove the oil filler cap sub-assembly.

2. REMOVE VENTILATION VALVE SUB-ASSEMBLY

(a) Remove the ventilation valve sub-assembly.

3. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the bolt and camshaft position sensor.

4. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the bolt and crankshaft position sensor.

5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Remove the bolt and camshaft timing oil control valve.

6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove the 19 bolts, 2 nuts, head cover and 2 gaskets.

7. REMOVE CRANKSHAFT PULLEY

(a) Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover.

(b) Check that the timing marks of the camshaft timing gear and sprocket are aligned with the timing marks of the bearing cap No.1, as shown in the illustration.

(c) Using SST, loosen the crankshaft pulley bolt.

SST : 09213-54015

91651-60855

SST : 09330-00021

(d) Using SST, remove the crankshaft pulley bolt and crankshaft pulley.

SST : 09950-50013

09951-05010

09952-05010

09953-05010

09954-05021

8. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the drain plug and gasket.

(b) Remove the 18 bolts and 2 nuts.

(c) Insert the blade of oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the oil pan sub-assembly No.2.

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

9. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the 2 bolts, 2 nuts, oil strainer and gasket.

10. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 16 bolts and 2 nuts.

(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 O-ring.

11. REMOVE TIMING CHAIN COVER

(a) Remove the 19 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.

HINT
Tape the screwdriver tip before use.

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

(c) Remove the 3 O-rings.

(d) Using a 10 mm socket hexagon wrench, remove the timing chain cover plug.

12. REMOVE WATER PUMP ASSEMBLY

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

13. REMOVE TIMING CHAIN GUIDE

(a) Remove the 2 bolts, timing chain guide and O-ring.

14. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

NOTICE:
* When the chain tensioner is removed, do not rotate the crankshaft.
* When the chain is removed and the camshaft needs to be rotated, rotate the crankshaft 90 degrees to the right.
(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 bolt, nut, chain tensioner assembly No.1 and gasket.

15. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the bolt and tensioner slipper.

16. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the bolt, nut, and vibration damper.

17. REMOVE CHAIN SUB-ASSEMBLY

(a) Remove the chain.

18. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

(a) Remove the crankshaft timing gear from the crankshaft.

19. REMOVE CAMSHAFT BEARING CAP

(a) Uniformly loosen and remove the 21 bearing cap bolts and 20 washers on the camshafts in the sequence shown in the illustration.

(b) Remove the oil delivery pipe and O-ring from the bearing caps.

20. REMOVE CAMSHAFT

(a) Remove the camshaft sub-assembly.

21. REMOVE NO.2 CAMSHAFT

(a) Remove the No.2 camshaft sub-assembly.

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

(a) Remove the 16 valve rocker arm sub-assembly.

23. REMOVE CAMSHAFT TIMING SPROCKET

(a) Fix the camshaft with a vise and then remove the sprocket bolt and camshaft timing sprocket.

NOTICE:
Be careful not to damage the camshaft.

24. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

(a) Check the lock of the camshaft timing gear.

(1) Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked.

NOTICE:
Be careful not to damage the camshaft.

(b) Release the lock pin.

(1) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

HINT
2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece.

(2) Break through the tape of the advance side path and the retard side path on the opposite side to the hole of the advance side path, as shown in the illustration.

(3) Apply approximately 200 kPa (2.0 kgf*cm2, 28 psi) of air pressure to the two broken paths.

CAUTION:
Some oil splashing will occur. Cover the paths with a shop rag.

(4) Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path.

OK:

Gear rotates in the advance direction.

HINT
This operation releases the lock pin for the most retarded position.

(5) When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path, in that order.

NOTICE:
Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

(c) Check for smooth rotation.

(1) Rotate the camshaft timing gear within its movable range several times, but do not turn it to the most retarded position. Check that the gear rotates smoothly.

OK:

Gear rotates in the advance direction.

CAUTION:
Do not use an air pressure to perform the smooth operation check.

(d) Check the lock in the most retarded position.

(1) Confirm that the camshaft timing gear is locked at the most retarded position.

25. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

(a) Remove the fringe bolt and camshaft timing gear.

NOTICE:
* Be sure not to remove the other 3 bolts.
* If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.
26. REMOVE CYLINDER HEAD SUB-ASSEMBLY

(a) Uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

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

27. REMOVE CYLINDER HEAD GASKET

(a) Remove the cylinder head and gasket.

28. REMOVE NO. 2 CHAIN VIBRATION DAMPER

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

(b) Move the stopper plate upward to set the lock, and insert a hexagon wrench into the stopper plate's hole.

(c) Remove the bolt and chain vibration damper No.2.

29. REMOVE NO. 3 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and chain vibration damper No.3.

30. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Remove the hexagon wrench from the tensioner assembly No.2.

(b) Remove the nut and chain tensioner assembly No.2.

31. REMOVE NO.2 CHAIN SUB-ASSEMBLY

(a) Remove the bolt, balanceshaft drive gear shaft and balanceshaft drive gear.

(b) Remove the crankshaft timing sprocket No.2 and chain.

32. REMOVE NO. 4 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and vibration damper No.4.

33. REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY

(a) Remove the 2 pulley set keys from the crankshaft.

34. REMOVE OIL FILTER SUB-ASSEMBLY

(a) Using SST, remove the oil filter.

SST : 09228-07501

(b) Using a 27 mm socket wrench, remove the oil filter union.