Part 1

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

DISASSEMBLY
HINT:
- Thoroughly clean all the disassembled parts before reassembly.
- 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 No. 1 engine hanger.
(b) Remove the 2 bolts and No. 2 engine hanger.

2. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a) Remove the engine coolant temperature sensor and gasket.

3. REMOVE WATER BY-PASS JOINT RR
(a) Remove the 2 bolts, 4 nuts and the water by-pass rear joint.
(b) Remove the 2 gaskets from the cylinder head.
(c) Remove the O-ring from the outlet pipe.

4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1)
(a) Remove the bolt and camshaft timing oil control valve.

5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2)
(a) Remove the bolt and camshaft timing oil control valve.

6. REMOVE OIL FILTER SUB-ASSEMBLY
(a) Remove the drain pipe cap.
(b) While removing the oil filter with SST, catch the oil from the oil filter with a container.
SST: 09228-07501
(c) Install the drain pipe cap.
7. REMOVE OIL FILTER UNION
(a) Using a 12 mm hexagon wrench, remove the oil filter union.
8. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Using a 24 mm deep socket wrench, remove the oil pressure switch.

9. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY
(a) Remove the 3 bolts, 2 nuts and the oil filter bracket.
(b) Remove the gasket.
(c) Remove the 2 stud bolts.

10. REMOVE WITH THERMOSTAT WATER INLET SUB-ASSEMBLY
(a) Remove the 3 nuts and the water inlet with thermostat.
(b) Remove the O-ring.
11. REMOVE NO. 3 WATER BY-PASS HOSE
(a) Loosen the 2 clamps and remove the No. 3 water by-pass hose.
12. REMOVE NO. 2 WATER BY-PASS HOSE
(a) Loosen the 2 clamps and remove the No. 2 water by-pass hose.
13. REMOVE WATER BY-PASS HOSE
(a) Loosen the 2 clamps and remove the water by-pass hose.

14. REMOVE WATER INLET
(a) Remove the 5 bolts and water inlet.
(b) Remove the O-ring from the outlet pipe.
(c) Remove the gasket.
15. REMOVE SPARK PLUG
(a) Using a spark plug wrench, remove the 6 spark plugs.
16. REMOVE OIL LEVEL GAUGE GUIDE
(a) Remove the bolt, then pull out the oil level gauge guide.
(b) Remove the O-ring from the oil level gauge guide.
17. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Remove the 2 water drain cocks.

18. REMOVE VVT SENSOR
(a) Remove the 2 bolts, then remove the 2 VVT sensors.

19. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the bolt, then remove the crankshaft position sensor.

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

21. 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.

22. 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.
23. REMOVE CRANKSHAFT PULLEY

(a) Turn the crankshaft pulley until its groove and the "0" timing mark of the timing chain cover are aligned.

(b) Check that the timing marks of the camshaft timing gears are aligned with the timing marks 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.

(d) Using the pulley set bolt and SST, remove the crankshaft pulley.
SST: 09950-50013
09951-05010
09952-05010
09953-05020
09954-05030
24. REMOVE OIL PAN DRAIN PLUG
(a) Remove the drain plug and gasket.
25. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 10 bolts and 2 nuts.

(b) Insert the blade of SST between the oil pan and oil pan No. 2, then cut off applied sealer and remove oil pan No. 2.
- 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.

26. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the 2 nuts, then remove the oil strainer and gasket.
27. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 4 stud bolts from the oil pan.

(b) Remove the 17 bolts and 2 nuts.

(c) Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block in the sequence shown.
NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

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

28. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 17 bolts, then remove the water pump and gasket.
29. 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.
NOTE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head.

(c) Remove the 4 bolts and timing chain cover plate.
(d) Remove the O-ring from the cylinder head LH.
30. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
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 dia 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate.
(c) Remove the 2 bolts, then remove the chain tensioner.
31. REMOVE CHAIN TENSIONER SLIPPER

32. REMOVE NO. 1 IDLE GEAR
(a) Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, No. 1 idle gear and No. 1 idle gear shaft.

33. REMOVE NO. 2 CHAIN VIBRATION DAMPER
(a) Remove the 2 No. 2 chain vibration dampers.
34. REMOVE CHAIN SUB-ASSEMBLY
35. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

36. REMOVE NO. 1 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts, then remove the No. 1 chain vibration damper.
37. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

(a) While raising chain tensioner No. 2 upward, insert a pin of dia 1.0 mm (0.039 in.) 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 No. 2 timing chain.
- Be careful not to damage the cylinder head and valve lifter with the wrench.
- Do not disassemble the camshaft timing gear assembly.

38. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Remove the bolt, then remove the No. 2 chain tensioner.
39. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

(a) While pushing down the No. 3 chain tensioner, insert a pin of dia 1.0 mm (0.039 in.) into the hole to fix it.

40. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Remove the bolt, then remove the No. 3 chain tensioner.

41. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance:
0.04 to 0.09 mm (0.016 to 0.035 in.)
Maximum thrust clearance:
0.11 mm (0.0043 in.)
If the thrust clearance is greater than the maximum, replace the camshafts.
If necessary, replace the camshaft bearing caps and cylinder head as a set.
42. REMOVE CAMSHAFTS
NOTE: 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 force. This could subsequently lead the camshaft to seize or break. Perform the following steps to avoid such problems.

(a) Remove the camshafts of bank 1.

(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 bank 2.
(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.
43. REMOVE NO. 1 CAMSHAFT BEARING
(a) Remove the No. 1 camshaft bearing from the No. 1 camshaft bearing cap.