Disassembly
2GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY
1. REMOVE OIL FILLER CAP SUB-ASSEMBLY
(a) Remove the oil filler cap sub-assembly and oil filler gasket.
2. REMOVE SPARK PLUG Removal
3. REMOVE OIL PAN DRAIN PLUG
(a) Remove the oil pan drain plug and oil pan drain plug gasket.
4. REMOVE VENTILATION VALVE SUB-ASSEMBLY
(a) Remove the ventilation valve sub-assembly.
5. REMOVE CAMSHAFT POSITION SENSOR Removal
6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Removal
7. REMOVE CRANKSHAFT POSITION SENSOR Removal
8. REMOVE NO. 1 OIL PIPE
(a) Remove the 2 oil pipe unions, gaskets and No. 1 oil pipe.
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(b) Remove the oil control valve filter LH and gaskets.
9. REMOVE OIL PIPE
(a) Remove the bolt.
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(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 2 cylinder block water drain cock sub-assemblies from the cylinder block.
(b) Remove the 2 cylinder block water drain cock plugs from the 2 water drain cock sub-assemblies.
11. REMOVE OIL FILTER ELEMENT
(a) Remove the drain plug.
NOTICE:
Do not remove the O-ring from the oil filter cap.
(b) Connect the hose to the pipe.
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(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 sub-assembly.
SST : 09228-06501
(f) Remove the oil filter element and O-ring from the oil filter cap sub-assembly.
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NOTICE:
Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.
12. REMOVE CRANKSHAFT PULLEY Removal
13. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler)
(a) Remove the bolt, 2 clamps, and 4 clips and disconnect the 2 water by-pass hoses.
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(b) Remove the union bolt, oil cooler assembly, and O-ring.
14. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)
(a) Remove the 3 bolts, 3 nuts, and oil cooler pipe with the No. 1 oil cooler bracket.
(b) Remove the bolt, 2 nuts, No. 1 oil cooler bracket, and gasket.
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(c) Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
15. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE
(a) Remove the bolt and engine oil level dipstick guide.
(b) Remove the O-ring.
16. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH
(a) Remove the 6 bolts and front No. 1 engine mounting bracket LH.
(b) Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
17. REMOVE WATER INLET HOUSING
(a) Remove the 2 nuts, water inlet and thermostat.
(b) Remove the gasket.
(c) Remove the 2 stud bolts.
(d) Separate the No. 1 water by-pass hose from the water inlet housing.
(e) Remove the drain cock plug.
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(f) Remove the drain cock assembly.
(g) Remove the 2 bolts, nut, and water inlet housing.
(h) Remove the 2 O-rings.
18. REMOVE WATER OUTLET
(a) Remove the 2 bolts, 4 nuts and water outlet.
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(b) Remove the 2 gaskets and O-ring.
19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
(a) Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.
(b) Remove the 3 gaskets.
20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (for Bank 2)
(a) Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.
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NOTICE:
The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the cylinder head cover sub-assembly.
(b) Remove the 3 gaskets.
21. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
(a) Remove the 16 bolts and 2 nuts.
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(b) Insert the blade of the oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.
NOTICE:
Be careful not to damage the contact surfaces of the oil pans.
(c) Using an E6 "TORX" socket wrench, remove the 2 stud bolts.
22. REMOVE OIL STRAINER SUB-ASSEMBLY
(a) Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.
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(b) Using an E6 "TORX" socket wrench, remove the 2 stud bolts.
23. REMOVE OIL PAN SUB-ASSEMBLY
(a) Remove the 16 bolts and 2 nuts.
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HINT
Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.
(b) Remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly with a screwdriver.
Text in Illustration:
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.
(d) Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
24. REMOVE NO. 1 OIL PAN BAFFLE PLATE
(a) Remove the 7 bolts and No. 1 oil pan baffle plate.
25. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver, pry out the engine rear oil seal retainer.
NOTICE:
Be careful not to damage the engine rear oil seal retainer.
HINT
Tape the screwdriver tip before use.
26. REMOVE ENGINE REAR OIL SEAL
(a) Place the engine rear oil seal retainer on wooden blocks.
Text in Illustration:
(b) Using a screwdriver and a hammer, tap out the oil seal.
NOTICE:
Be careful not to damage the engine rear oil seal retainer.
HINT
Tape the screwdriver tip before use.
27. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal
28. REMOVE TIMING CHAIN CASE OIL SEAL Removal
29. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 8 bolts, water pump assembly and water pump gasket.
30. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Temporarily tighten the pulley set bolt.
(b) Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression).
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(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.
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(d) If not, turn the crankshaft clockwise 1 revolution (360°) and align the timing marks as above.
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.
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(b) Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm diameter (0.0500 in.) into the stopper plate 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 of the crankshaft timing sprocket.
(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 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) Removal
39. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY Removal
40. REMOVE CAMSHAFT BEARING CAP (for Bank 1) Removal
41. REMOVE CAMSHAFT Removal
42. REMOVE NO. 2 CAMSHAFT Removal
43. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH Removal
44. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) Removal
45. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY Removal
46. REMOVE CAMSHAFT BEARING CAP (for Bank 2) Removal
47. REMOVE NO. 3 CAMSHAFT Removal
48. REMOVE NO. 4 CAMSHAFT Removal
49. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH Removal
50. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Removal
51. REMOVE VALVE LASH ADJUSTER ASSEMBLY Removal
52. REMOVE VALVE STEM CAP Removal
53. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH Removal
54. REMOVE CYLINDER HEAD GASKET RH Removal
55. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH Removal
56. REMOVE CYLINDER HEAD GASKET LH Removal
57. 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.
