Installation and Removal -Print Preview- Page 1 of 39

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

a. Remove the spark plugs.

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

a. Remove the 4 bolts and 4 camshaft

position sensors.

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6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

a. Remove the 4 bolts and 4 camshaft oil

control valves.

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7. REMOVE CRANKSHAFT POSITION SENSOR

a. Remove the bolt and crankshaft position

sensor.

8. REMOVE NO. 1 OIL PIPE

a. Remove the 2 oil pipe unions, gaskets

and oil pipe.

b. Remove the oil control valve filter LH and

gaskets.

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9. REMOVE OIL PIPE

a. Remove the bolt.

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 cylinder block water drain

cocks from the cylinder block.

b. Remove the cylinder block water drain

cock plugs from the water drain cocks.

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a. Remove the drain plug.

NOTICE:
Do not remove the O-ring from the oil
filter cap.

b. Connect the hose to the pipe.

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

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f. Remove the oil filter element and O-ring

from the oil filter cap sub-assembly.

NOTICE:
Do not use any tools when removing
the O-ring to prevent the O-ring groove
from being damaged.

12. REMOVE CRANKSHAFT PULLEY

a. Using SST, loosen the crankshaft pulley

bolt.
SST
09213-70011 (09213-70020)
09330-00021

b. Using SST, remove the crankshaft pulley

bolt and crankshaft pulley.
SST

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09950-50013 (09951-
05010, 09952-05010, 09953-
05020, 09954-05021)

13. REMOVE OIL COOLER ASSEMBLY

a. Remove the bolt, 2 clamps, and 4 clips

and disconnect the 2 water by-pass
hoses.

b. Remove the union bolt, oil cooler

assembly, and O-ring.

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a. Remove the 3 bolts, 3 nuts, and oil

cooler pipe with No. 1 oil cooler bracket.

b. Remove the bolt, 2 nuts, No. 1 oil cooler

bracket, and gasket.

c. Using a "TORX" socket wrench E8,

remove the 2 stud bolts.

15. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH

a. Remove the 6 bolts and No. 1 front

engine mounting bracket LH.

b. Using a "TORX" socket wrench E8,

remove the 2 stud bolts.

16. REMOVE WATER INLET HOUSING

a. Remove the 2 nuts, water inlet and

thermostat.

b. Remove the gasket.

c. Remove the drain cock plug.

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d. Remove the drain cock assembly.

e. Remove the 2 stud bolts.

f. Separate the No. 1 water by-pass hose.

g. Remove the 2 bolts, nut, and water inlet

housing.

h. Remove the 2 O-rings.

a. Remove the 2 bolts, 4 nuts and water

outlet.

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b. Remove the 2 gaskets and O-ring.

18. 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.

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19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)

a. Remove the 12 bolts, seal washer,

cylinder head cover sub-assembly and
cylinder head cover gasket.

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 head cover.

b. Remove the 3 gaskets.

a. Remove the 16 bolts and 2 nuts.

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b. Insert the oil pan seal cutter blade

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 a "TORX" socket wrench E6,

remove the 2 stud bolts.

21. REMOVE OIL STRAINER SUB-ASSEMBLY

a. Remove the bolt, 2 nuts, oil strainer sub-

assembly and gasket.

b. Using a "TORX" socket wrench E6,

remove the 2 stud bolts.

a. Remove the 16 bolts and 2 nuts.

HINT:
Be sure to clean the bolts and stud
bolts and check the threads for cracks
or other damage.

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b. Remove the oil pan sub-assembly by

prying between the oil pan sub-assembly
and cylinder block sub-assembly 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 2 O-rings.

d. Using a "TORX" socket wrench E8,

remove the 2 stud bolts.

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23. REMOVE NO. 1 OIL PAN BAFFLE PLATE

a. Remove the 7 bolts and No. 1 oil pan

baffle plate.

24. 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.

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HINT:
Tape the screwdriver tip before use.

25. REMOVE ENGINE REAR OIL SEAL

a. Place the oil seal retainer on wooden

blocks.

NOTICE:
Be careful not to damage the engine
rear oil seal retainer.

b. Using a screwdriver and a hammer, tap

out the oil seal.

HINT:
Tape the screwdriver tip before use.

26. REMOVE WATER PUMP ASSEMBLY

a. Remove the 16 bolts, water pump

assembly and gasket.

a. Remove the 15 bolts and 2 nuts as

shown in the illustration.

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b. Remove the timing chain cover sub-

assembly by prying between the timing
chain cover and cylinder head sub-
assembly or cylinder block sub-assembly
with a screwdriver.

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

HINT:
Tape the screwdriver tip before use.

c. Remove the 4 bolts, chain cover plate

and chain cover plate gasket.

d. Remove the gasket.

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28. REMOVE TIMING CHAIN CASE OIL SEAL

a. Using a screwdriver, pry out the timing

chain case oil seal.

HINT:
Tape the screwdriver tip before use.

29. SET NO. 1 CYLINDER TO TDC / COMPRESSION

a. Temporarily tighten the pulley set bolt.

b. Set the timing mark on the crank angle

sensor plate to the RH block bore center
line (TDC / compression).

c. Check that the timing marks of the

camshaft timing gears are aligned with
those of the bearing cap as shown in the
illustration.
If not, turn the crankshaft 1 revolution

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(360°) and align the timing marks as

above.

30. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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 pin of φ1.27 mm
(0.05 in.) into the stopper plate's hole.

c. Remove the 2 bolts and No. 1 chain

tensioner assembly.

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31. REMOVE CHAIN TENSIONER SLIPPER

a. Remove the chain tensioner slipper.

32. REMOVE CHAIN SUB-ASSEMBLY

a. Turn the crankshaft counterclockwise 10°

to loosen the chain sub-assembly 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 the bank 1 clockwise (approximately
60°) and set it as shown in the

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illustration. Be sure to loosen the chain

between the banks.

e. Remove the chain.

33. 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.

34. REMOVE NO. 1 CHAIN VIBRATION DAMPER

a. Remove the 2 bolts and No. 1 chain

vibration damper.

35. REMOVE NO. 2 CHAIN VIBRATION DAMPER

a. Remove the 2 No. 2 chain vibration dampers.

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a. Remove the crankshaft timing sprocket

from the crankshaft.

b. Remove the 2 keys from the crankshaft.

37. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

a. While raising the No. 2 chain tensioner

assembly, insert a pin of φ1.0 mm
(0.039 in.) into the hole to fix the No. 2
chain tensioner.

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
RH.
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

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gear assembly RH together with the No. 2 chain.

38. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

a. Remove the bolt and No. 2 chain

tensioner assembly.

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.

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c. Uniformly loosen and remove the 12

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.

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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 φ1.0
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

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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.

a. Check that the camshafts are positioned

as shown in the illustration.

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b. Uniformly loosen and remove the 8

bearing cap bolts in the sequence shown
in the illustration.

c. Uniformly loosen and remove the 13

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.

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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.

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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:
l Be careful not to drop washers into
the cylinder head.
l 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:
l Be careful not to drop washers into
the cylinder head.
l Cylinder head warpage or cracking
could result from removing bolts in
an incorrect order.

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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.

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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.

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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.

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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.

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

b. Place the cylinder head on wooden blocks.

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c. Using SST and a hammer, tap out the

intake valve guide bushes.
SST
09201-10000 (09201-01050)
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)
09950-70010 (09951-07100)

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.

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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:
l Keep the bearing, connecting rod
and cap together.
l 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.

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

d. Remove the crankshaft.

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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.

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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.

a. Check the fitting condition between the

piston and piston pin.

i. 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.

i. Using a screwdriver, pry off the piston

pin hole snap rings from the piston.

ii. Gradually heat the piston to

approximately 80°C (176°F).

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iii. Using a brass bar and plastic hammer,

lightly tap out the piston pin and
remove the connecting rod.

HINT:
l The piston and pin are a
matched set.
l 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.

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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

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