Part 1

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY
2. REMOVE SPARK PLUG
3. REMOVE CAMSHAFT TIMING CONTROL VALVE ASSEMBLY Removal

4. REMOVE VVT SENSOR Removal

5. REMOVE WATER OUTLET

(a) Remove the 2 bolts, 4 nuts and water outlet.

(b) Remove the 2 gaskets and O-ring.
6. REMOVE OIL PIPE

(a) Remove the bolt, 2 union bolts and oil pipe.
(b) Remove the oil control valve filter RH and gaskets.
7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)

(a) Remove the 12 bolts, cylinder head cover and gasket.
HINT: Make sure the removed parts are returned to the same places they were removed from.

8. REMOVE NO. 1 OIL PIPE

(a) Remove the 2 union bolts and oil pipe.
(b) Remove the oil control valve filter LH and gaskets.
9. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)

(a) Remove the 12 bolts, cylinder head cover and gasket.
HINT: Make sure the removed parts are returned to the same places they were removed from.

10. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET

(a) Remove the 6 bolts and mounting bracket.
11. REMOVE WATER INLET HOUSING Removal

12. REMOVE OIL FILTER CAP ASSEMBLY Replacement

13. REMOVE OIL FILTER ELEMENT Replacement

14. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY Removal

15. REMOVE OIL STRAINER SUB-ASSEMBLY Removal

16. REMOVE OIL PAN SUB-ASSEMBLY Removal

17. REMOVE OIL PAN BAFFLE PLATE NO.1

(a) Remove the 7 bolts and baffle plate.
18. REMOVE CRANKSHAFT PULLEY

(a) Using SST, loosen the crankshaft pulley set bolt.
SST: 09213-70011
09213-70020
SST: 09330-00021

(b) Using the pulley set bolt and SST, remove the crankshaft pulley.
SST: 09950-50013
09951-05010
09952-05010
09953-05020
09954-05021
19. REMOVE WATER PUMP ASSEMBLY Removal

20. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 6 bolts.

(b) Using a screwdriver, pry out the oil seal retainer.
HINT: Tape the screwdriver tip before use.

21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (w/ Oil Pump) Removal

22. 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 the timing marks of the bearing cap as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.
23. 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 hexagon wrench into the stopper plate hole.
(c) Remove the 2 bolts and chain tensioner.
24. REMOVE CHAIN TENSIONER SLIPPER
25. REMOVE NO. 1 CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing gear.
(b) Remove the chain from the crankshaft timing gear and place it on the crankshaft.

(c) Turn the camshaft timing gear on the Bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the center banks.
(d) Remove the chain.
26. REMOVE IDLE SPROCKET ASSEMBLY

(a) Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket and No. 1 idle gear shaft.
27. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and vibration damper.
28. REMOVE NO. 2 CHAIN VIBRATION DAMPER
(a) Remove the 2 chain vibration dampers.
29. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
(a) Remove the pulley set bolt.

(b) Remove the crankshaft timing gear from the crankshaft.
(c) Remove the 2 pulley set keys from the crankshaft.
30. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 1)

(a) While raising the No. 2 chain tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix the No. 2 chain tensioner.

(b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gears.
- Be careful not to damage the cylinder head with the wrench.
- Do not disassemble the camshaft timing gear.

(c) Remove the No. 2 chain.
31. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt and chain tensioner.
32. REMOVE CAMSHAFT (for Bank 1)

(a) Remove the 3 gaskets.

(b) Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

(d) Uniformly loosen and remove the 12 bearing cap bolts in the sequence shown in the illustration.
NOTE: Uniformly loosen the bolts while keeping the camshaft level.

(e) Remove the 5 bearing caps.
(f) Remove the No. 1 and No. 2 camshafts.
33. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 1)

(a) While pushing down the No. 3 chain tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix the No. 3 chain tensioner.

(b) Hold the hexagonal portion of the camshaft with a wrench and remove the 2 bolts and 2 camshaft timing gears.
- Be careful not to damage the cylinder head with the wrench.
- Do not disassemble the camshaft timing gear.

(c) Remove the No. 2 chain.
35. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt and chain tensioner.
36. REMOVE CAMSHAFT SUB-ASSEMBLY (for Bank 2)

(a) Remove the 3 gaskets.

(b) Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

(d) Uniformly loosen and remove the 13 bearing cap bolts in the sequence shown in the illustration.
NOTE: Uniformly loosen the bolts while keeping the camshaft level.

(e) Remove the 5 bearing caps.
(f) Remove the No. 3 and No. 4 camshafts.
37. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 2)

(a) Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.
NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.
HINT: Tape the screwdriver tip before use.

38. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Remove the 24 valve rocker arms.
HINT: Arrange the removed parts in the correct order.

39. REMOVE VALVE LASH ADJUSTER ASSEMBLY
(a) Remove the 24 valve lash adjusters from the cylinder head.
HINT: Arrange the removed parts in the correct order.

40. REMOVE CYLINDER HEAD SUB-ASSEMBLY (for Bank 1)

(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.
- Be careful not to drop washers into the cylinder head.
- Head warpage or cracking could result from removing bolts in an incorrect order.
HINT: Be sure to keep the removed parts separate for each installation position.

(b) Remove the cylinder head and gasket.