Part 1

PARTIAL ENGINE ASSEMBLY (1GR-FE)






































COMPONENTS

OVERHAUL

HINT:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets, O-rings and oil seals with new parts.





1. REMOVE ENGINE HANGERS
a. Remove the 2 bolts and engine hanger No.1.
b. Remove the 2 bolts and engine hanger No.2.
2. REMOVE OIL LEVEL GAGE GUIDE
a. Remove the bolt, then pull out the oil level gauge guide.
b. Remove the O-ring from the oil level gauge guide.
3. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (at Remove the 2 water drain cocks.





4. REMOVE WT SENSOR
a. Remove the 2 bolts, then remove the 2 WT sensors.





5. REMOVE CRANKSHAFT POSITION SENSOR
a. Remove the bolt, then remove the crankshaft position sensor.





6. REMOVE OIL CONTROL VALVE FILTER
a. Remove the plug and filter, then remove the gasket from each cylinder head.





7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove the 10 bolts, 3 seal washers and 2 nuts, then remove the cylinder head cover.
b. Remove the gasket from the cylinder head cover.





8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
a. Remove the 10 bolts, 3 seal washers and 2 nuts, then remove the cylinder head cover.
b. Remove the gasket from the cylinder head cover.
c. Remove the ventilation valve from the cylinder head cover.





9. REMOVE CRANKSHAFT PULLEY
a. Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned.





b. Check that each timing mark of the camshaft timing gears is aligned with each timing mark located on the No.1 and No.2 bearing caps as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.





c. Using SST, fix the pulley and loosen the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021





d. Using the pulley set bolt and SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05030)
10. REMOVE OIL PAN DRAIN PLUG
a. Remove the drain plug and gasket.





11. REMOVE OIL PAN SUB-ASSEMBLY NO.2
a. Remove the 15 bolts and 2 nuts (for 2WD).





b. Remove the 10 bolts and 2 nuts (for Pre Runner and 4WD).





c. Insert the blade of SST between the oil pan and oil pan No.2, then cut off applied sealer and remove the oil pan No.2.
SST 09032-00 100

NOTICE:
- Be careful not to damage the contact surface of the oil pan and oil pan No.2.
- Be careful not to damage the oil pan No.2 flange.





12. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the 2 nuts, then remove the oil strainer and gasket (for 2WD).





b. Remove the 2 nuts, then remove the oil strainer and gasket (for Pre Runner and 4WD).





13. REMOVE OIL PAN SUB-ASSEMBLY
a. Remove the 17 bolts and 2 nuts (for 2WD).





b. Remove the 17 bolts and 2 nuts (for Pre Runner and 4WD).





c. Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block in the sequence shown.

NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

d. Remove the O-ring from the oil pump.





14. REMOVE WATER PUMP ASSEMBLY
a. Remove the 17 bolts, then remove the water pump and gasket.





15. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove the 15 bolts and 2 nuts.





b. Remove the timing chain cover by prying between the timing chain cover, cylinder head and cylinder block with a screwdriver.

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

c. Remove the O-ring from the LH cylinder head.





16. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
a. Using a screwdriver, pry out the oil seal.

NOTICE: Be careful not to damage the oil pump assembly. Wrap a tip of the screwdriver with tape.

17. REMOVE CHAIN TENSIONER ASSEMBLY NO.1

NOTICE:
- Never rotate the crankshaft with the chain tensioner removed.
- When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.





a. While turning the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration.
b. While turning the stopper plate of the tensioner downward, insert a bar of 3.5 mm (0.138 inch) into the holes in the stopper plate and tensioner to fix the stopper plate.
c. Remove the 2 bolts, then remove the chain tensioner.
18. REMOVE CHAIN TENSIONER SLIPPER





19. REMOVE IDLE SPROCKET ASSEMBLY
a. Using a 10 mm hexagon wrench, remove the idle gear shaft No.2, idle gear No.1 and idle gear shaft No.1.





20. REMOVE CHAIN VIBRATION DAMPER NO.2
a. Remove the 2 chain vibration dampers No.2.
21. REMOVE CHAIN SUB-ASSEMBLY
22. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET





23. REMOVE CHAIN VIBRATION DAMPER NO.1
a. Remove the 2 bolts, then remove the chain vibration damper No.1.





24. REMOVE CAMSHAFT TIMING GEARS AND NO.2 CHAIN (RH BANK)
a. While raising the chain tensioner No.2 upward, insert a pin of 1.0 mm (0.039 inch) into the hole to fix it.





b. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and timing chain No.2.

NOTICE:
- Be careful not to damage the cylinder head and valve lifter with the wrench.
- Do not disassemble the camshaft timing gear assembly.





25. REMOVE CHAIN TENSIONER ASSEMBLY NO.2
a. Remove the bolt, then remove the chain tensioner No.2.





26. REMOVE CAMSHAFT TIMING GEARS AND NO.2 CHAIN (LH BANK)
a. While pushing down the chain tensioner No.3, insert a pin of 1.0 mm (0.039 inch) into the hole to fix it.





b. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and timing chain No.2.

NOTICE:
- Be careful not to damage the cylinder head and valve lifter with the wrench.
- Do not disassemble the camshaft timing gear assembly.





27. REMOVE CHAIN TENSIONER ASSEMBLY NO.3





a. Remove the bolt, then remove the chain tensioner No.3.
28. REMOVE CAMSHAFTS

NOTICE: Keep the camshaft level while it is being removed. The camshaft thrust clearance is very small and failing to keep it level could crack or damage the cylinder head journal surface, which receives the thrust. This could subsequently lead the camshaft to seize or break. Perform the following steps to avoid such problems.

a. Remove the camshafts of the RH bank.
(1) Rotate the camshafts counterclockwise using a wrench so that cam lobes of No.1 cylinder face in the directions as shown in the illustration.





(2) Using several steps, uniformly loosen and remove the 16 bearing cap bolts in the sequence shown in the illustration.
(3) Remove the 8 bearing caps, then remove the 2 camshafts.





b. Remove the camshafts of the LH bank.
(1) Using several steps, uniformly loosen and remove the 16 bearing cap bolts in the sequence shown in the illustration.
(2) Remove the 8 bearing caps, then remove the 2 camshafts.
29. REMOVE CAMSHAFT BEARING NO.1
30. REMOVE CAMSHAFT BEARING NO.2





31. REMOVE CYLINDER HEADS
a. Using several steps, remove the 2 cylinder head bolts on the LH cylinder head in the sequence shown in the illustration.





b. Using several steps, loosen the 8 cylinder head bolts on each cylinder head with a 10 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 16 cylinder head bolts, then remove the plate washers.

NOTICE:
- Be careful not to drop the plate washers into the cylinder head.
- Cylinder head warpage or cracking could result from removing the bolts in the wrong order.





c. Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench.

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

HINT: If the cylinder head is difficult to remove, pry between the cylinder head and cylinder block with a screwdriver.

d. Remove the RH and LH cylinder head gaskets.





32. REMOVE WATER OUTLET PIPE NO.1
a. Separate the knock sensor wire.
b. Remove the 3 bolts, then remove the water outlet pipe.





33. REMOVE KNOCK CONTROL SENSOR
a. Disconnect the knock sensor connectors.
b. Remove the 2 bolts, then remove the 2 knock sensors.





34. REMOVE ENGINE REAR OIL SEAL RETAINER
a. Remove the 5 bolts and 2 nuts.
b. Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and crankshaft bearing cap.





35. REMOVE ENGINE REAR OIL SEAL
a. Using a screwdriver and hammer, tap the oil seal out.





36. INSPECT CAMSHAFTS
a. Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at the center journal.
Maximum runout: 0.06 mm (0.0024 inch)
If the circle runout is greater than the maximum, replace the camshaft.





b. Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake 44.168 to 44.268 mm (1.7389 to 1.7428 inch)
Exhaust 44.580 to 44.680 mm (1.7551 to 1.7591 inch)
Minimum cam lobe height:
Intake 44.018 mm (1.7330 inch)
Exhaust 44.430 mm (1.7492 inch)
If the cam lobe height is less than the minimum, replace the camshaft.





c. Inspect the camshaft journals.
(1) Using a micrometer, measure the journal diameter.
No.1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 inch)
Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 inch)
If the journal diameter is not as specified, check the oil clearance.