Disassembly
2AR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY
1. REMOVE ENGINE COVER JOINT
(a) Remove the 3 joints.
2. REMOVE SPARK PLUG Removal
3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Removal
4. REMOVE CAMSHAFT POSITION SENSOR Removal
5. REMOVE OIL FILLER CAP SUB-ASSEMBLY
(a) Remove the oil filler cap from the cylinder head.
(b) Remove the gasket from the oil filler cap.
6. REMOVE CRANKSHAFT POSITION SENSOR Removal
7. REMOVE VENTILATION VALVE SUB-ASSEMBLY Removal
8. REMOVE VENTILATION CASE SUB-ASSEMBLY
(a) Remove the 8 bolts and 2 nuts.
(b) Remove the ventilation case by prying between the ventilation case and cylinder block with a screwdriver.
HINT
Tape the screwdriver tip before use.
NOTICE:
Be careful not to damage the contact surfaces of the cylinder block and ventilation case.
9. REMOVE SEPARATOR CASE
(a) Remove the 2 bolts, separator case and gasket.
10. REMOVE NO. 1 WATER BY-PASS PIPE
(a) Remove the bolt, 2 nuts, water by-pass pipe and gasket.
11. REMOVE WATER INLET Removal
12. REMOVE THERMOSTAT Removal
13. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the bolt and V-ribbed belt tensioner.
14. REMOVE ENGINE WATER PUMP ASSEMBLY Removal
15. REMOVE WATER INLET HOUSING
(a) Remove the 4 bolts, nut, inlet water housing and gasket.
16. REMOVE CRANKSHAFT PULLEY
(a) Using SST, hold the crankshaft pulley and loosen the pulley bolt. Further loosen the bolt until 2 or 3 threads are screwed into the crankshaft.
Text in Illustration
SST : 09213-54015
SST : 09330-00021
SST : 91551-80650
(b) Using SST and the pulley bolt, remove the crankshaft pulley.
Text in Illustration
SST : 09950-50013
09951-05010
09952-05010
09953-05020
09954-05011
HINT
Apply a lubricant to the threads and end of SST.
17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove the 16 bolts, 3 seal washers, cylinder head cover and gasket.
(b) Remove the 3 gaskets from the camshaft bearing caps.
18. REMOVE SPARK PLUG TUBE GASKET
(a) Using a screwdriver, pry out the 4 plug tube gaskets.
NOTICE:
Be careful not to damage the cylinder head cover.
HINT
Tape the screwdriver tip before use.
19. REMOVE ENGINE MOUNTING BRACKET RH Removal
20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal
21. REMOVE TIMING CHAIN COVER TIGHT PLUG
(a) Using a 14 mm hexagon wrench, remove the plug and gasket.
22. REMOVE TIMING CHAIN COVER PLATE
(a) Remove the 4 bolts, timing chain cover plate and gasket.
23. REMOVE TIMING CHAIN COVER OIL SEAL Removal
24. SET NO. 1 CYLINDER TO TDC/COMPRESSION Removal
25. REMOVE TIMING CHAIN GUIDE Removal
26. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Removal
27. REMOVE CHAIN TENSIONER SLIPPER Removal
28. REMOVE CHAIN SUB-ASSEMBLY
(a) Remove the chain sub-assembly.
29. REMOVE NO. 1 CHAIN VIBRATION DAMPER Removal
30. REMOVE CRANKSHAFT TIMING SPROCKET
(a) Remove the crankshaft timing sprocket from the crankshaft.
31. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY Removal
32. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Removal
33. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY Removal
34. REMOVE CAMSHAFT BEARING CAP Removal
35. REMOVE OIL CONTROL VALVE FILTER
(a) Remove the oil control valve filter from the No. 1 camshaft bearing cap.
36. REMOVE CAMSHAFT Removal
37. REMOVE NO. 1 CAMSHAFT BEARING
(a) Remove the No. 1 camshaft bearing.
38. REMOVE NO. 2 CAMSHAFT BEARING
(a) Remove the No. 2 camshaft bearing.
39. REMOVE CAMSHAFT HOUSING STUD BOLT
NOTICE:
If a stud bolt is deformed or its threads are damaged, replace it.
40. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN
NOTICE:
It is not necessary to remove the ring pin unless it is being replaced.
41. REMOVE CAMSHAFT HOUSING STRAIGHT PIN
NOTICE:
It is not necessary to remove the straight pin unless it is being replaced.
42. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Removal
43. REMOVE VALVE LASH ADJUSTER ASSEMBLY Removal
44. REMOVE VALVE STEM CAP Removal
45. REMOVE CYLINDER HEAD SUB-ASSEMBLY Removal
46. REMOVE CYLINDER HEAD GASKET Removal
47. REMOVE CYLINDER BLOCK WATER JACKET SPACER
(a) Remove the cylinder block water jacket spacer from the cylinder block.
NOTICE:
Be sure to remove the water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block is inverted.
48. REMOVE OIL FILTER CAP ASSEMBLY Replacement
49. REMOVE OIL PAN SUB-ASSEMBLY
(a) Remove the 11 bolts and 2 nuts.
Text in Illustration
(b) Insert the blade of an oil pan seal cutter between the oil pan and stiffening crankcase, cut off the applied sealer and remove the oil pan.
NOTICE:
* Be careful not to damage the stiffening crankcase contact surface of the oil pan.
* Be careful not to damage the stiffening crankcase flange.
50. REMOVE OIL STRAINER SUB-ASSEMBLY
(a) Remove the 3 bolts, oil strainer and gasket.
51. REMOVE NO. 1 OIL PAN BAFFLE PLATE
(a) Remove the 5 bolts and oil pan baffle plate.
52. INSPECT CRANKSHAFT BACKLASH
(a) Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.
Standard backlash:
0.005 to 0.020 mm (0.000197 to 0.000787 in.)
Maximum backlash:
0.020 mm (0.000787 in.)
If the backlash is more than the maximum, replace the engine balancer assembly.
53. REMOVE ENGINE BALANCER ASSEMBLY
(a) Remove the 7 bolts and engine balancer.
NOTICE:
Do not disassemble the engine balancer.
54. INSPECT BALANCE SHAFT THRUST CLEARANCE Engine Unit
55. REMOVE STIFFENING CRANKCASE ASSEMBLY
(a) Remove the 7 bolts.
(b) Using a screwdriver, remove the stiffening crankcase by prying between the stiffening crankcase and cylinder block at the places shown in the illustration.
Text in Illustration
HINT
Tape the screwdriver tip before use.
NOTICE:
Be careful not to damage the contact surfaces of the cylinder block and stiffening crankcase.
56. REMOVE STIFFENING CRANKCASE STUD BOLT
NOTICE:
If a stud bolt is deformed or its threads are damaged, replace it.
57. REMOVE STIFFENING CRANKCASE RING PIN
NOTICE:
It is not necessary to remove the ring pin unless it is being replaced.
58. REMOVE REAR ENGINE OIL SEAL
(a) Remove the rear engine oil seal from the cylinder block.
