Part 2

2GR-FE ENGINE MECHANICAL: ENGINE UNIT:

DISASSEMBLY (Continued)

36. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt and No. 2 chain tensioner.
37. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

(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.

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

(d) Remove the 5 bearing caps.
38. REMOVE CAMSHAFT
(a) Remove the camshaft.
39. REMOVE NO. 2 CAMSHAFT
(a) Remove the No. 2 camshaft.
40. 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.
NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.
HINT: Tape the screwdriver tip before use.

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

(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 gear assemblies.
- Be careful not to damage the cylinder head with the wrench.
- Do not disassemble the camshaft timing gear assemblies.

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

(a) Remove the bolt and No. 3 chain tensioner.
43. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

(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.

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

(d) Remove the 5 bearing caps.
44. REMOVE NO. 3 CAMSHAFT
(a) Remove the No. 3 camshaft.
45. REMOVE NO. 4 CAMSHAFT
(a) Remove the No. 4 camshaft.
46. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

(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.

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

48. 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.

49. 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.
- Be careful not to drop the washers into the cylinder head.
- Cylinder head warpage or cracking could result from removing the bolts in an incorrect order.
HINT: Be sure to keep separate the removed parts for each installation position.

(b) Remove the cylinder head and gasket.
50. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

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

(c) Remove the cylinder head and gasket.
51. REMOVE WATER INLET PIPE
(a) Separate the No. 1 water by-pass hose.

(b) Remove the 2 bolts and water inlet pipe.
52. REMOVE VALVE STEM CAP
(a) Remove the valve stem caps from the cylinder heads.
HINT: Arrange the removed parts in the correct order.

53. REMOVE INTAKE VALVE

(a) Using SST, compress the compression spring and remove the valve spring retainer locks.
SST: 09202-70020
09202-00010
(b) Remove the retainer, compression spring, and valve.
HINT: Arrange the removed parts in the correct order.

54. REMOVE EXHAUST VALVE

(a) Using needle-nose pliers, remove the oil seals.
56. REMOVE VALVE SPRING SEAT

(a) Using compressed air and a magnetic finger, remove the valve spring seats by blowing air onto them.
57. REMOVE NO. 1 STRAIGHT SCREW PLUG

(a) Using a 10 mm hexagon wrench, remove the 4 screw plugs and 4 gaskets.
NOTE: If water leaks from the straight screw plug or the plug corrodes, replace it.

58. REMOVE NO. 2 STRAIGHT SCREW PLUG

(a) Using a 14 mm hexagon wrench, remove the screw plugs and gaskets.
NOTE: If water leaks from the straight screw plug or the plug corrodes, replace it.

59. REMOVE RING PIN
NOTE: It is not necessary to remove the ring pin unless it is being replaced.

60. REMOVE STUD BOLT
NOTE: If the stud bolt is deformed or the threads are damaged, replace it.

61. REMOVE INTAKE 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 guide bushes.
SST: 09201-10000
09201-01050
SST: 09950-70010
09951-07100
62. 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 guide bushes.
SST: 09201-10000
09201-01050
SST: 09950-70010
09951-07100
63. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD
(a) Check that the matchmarks on the connecting rod and cap are aligned.
HINT: The matchmarks on the connecting rods and caps are for ensuring the correct reassembly.

(b) Remove the 2 connecting rod cap bolts.

(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:
- Keep the bearing, connecting rod, and cap together.
- Arrange the piston and connecting rod assemblies in the correct order.

64. REMOVE CONNECTING ROD BEARING
HINT: Arrange the removed parts in the correct order.

65. REMOVE CRANKSHAFT

(a) Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in several steps and in the sequence shown in the illustration.

(b) Uniformly loosen the 16 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 main bearing caps and lower bearings.
NOTICE :
- Push up on the cap little by little, from the right and left side alternately so that the cap can be removed.
- Be careful not to damage the joint surfaces of the cylinder block and the main bearing cap.

(d) Remove the crankshaft.
66. REMOVE CRANKSHAFT BEARING
HINT: Arrange the removed parts in the correct order.

67. REMOVE CRANKSHAFT THRUST WASHER SET

(a) Remove the upper bearings and upper thrust washers from the cylinder block.
68. REMOVE PISTON RING SET

(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.

69. REMOVE PISTON SUB-ASSEMBLY WITH PIN

(a) Check the fitting condition between the piston and piston pin.
(1) 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.

(1) Using a screwdriver, pry off the snap rings from the piston.

(2) Gradually heat the piston to approximately 80°C (176°F).

(3) Using a brass bar and plastic hammer, lightly tap out the piston pin and remove the connecting rod.
HINT :
- The piston and pin are a matched set.
- Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

(d) Using a groove cleaning tool or broken ring, clean the piston ring grooves.

(e) Using solvent and a brush, thoroughly clean the piston.
NOTE: Do not use a wire brush.

70. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, remove the bolts and oil nozzles.
(b) Check the 3 oil nozzles for damage or clogging.
If necessary, replace the oil nozzle.
71. CLEAN CYLINDER BLOCK