3UR-FE Engine unit - DIsassembly

1. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

2. REMOVE OIL FILTER ELEMENT

3. REMOVE NO. 1 OIL COOLER BRACKET

4. REMOVE OIL FILTER BRACKET

5. REMOVE OIL FILLER CAP SUB-ASSEMBLY

6. REMOVE OIL FILLER CAP HOUSING

7. REMOVE SPARK PLUG

8. REMOVE VVT SENSOR

9. REMOVE CAMSHAFT POSITION SENSOR

10. REMOVE CRANK POSITION SENSOR PROTECTOR

11. REMOVE CRANKSHAFT POSITION SENSOR

12. REMOVE CAMSHAFT OIL CONTROL VALVE ASSEMBLY

13. REMOVE WATER PUMP PULLEY

14. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

15. REMOVE FLUID COUPLING BRACKET

16. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH

19. REMOVE OIL CONTROL VALVE FILTER

20. REMOVE SPARK PLUG TUBE GASKET

21. REMOVE CRANKSHAFT PULLEY

22. REMOVE WATER PUMP ASSEMBLY

23. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

24. REMOVE WATER INLET PIPE

25. REMOVE FRONT CRANKSHAFT OIL SEAL

26. SET NO. 1 CYLINDER TO TDC/COMPRESSION

27. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH

28. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

29. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH

30. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH

31. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

32. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH

33. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

34. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH

35. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH

36. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

37. REMOVE CRANKSHAFT TIMING GEAR KEY

38. REMOVE CAMSHAFT BEARING CAP LH

39. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

40. REMOVE CAMSHAFT BEARING CAP RH

41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

42. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

43. REMOVE VALVE LASH ADJUSTER ASSEMBLY

44. REMOVE VALVE STEM CAP

45. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

46. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

47. REMOVE CYLINDER BLOCK WATER JACKET SPACER

48. REMOVE VENTILATION PIPE GASKET

49. REMOVE NO. 1 HEAT EXCHANGER COVER

50. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

51. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY

52. REMOVE NO. 1 OIL PAN BAFFLE PLATE

53. REMOVE OIL STRAINER SUB-ASSEMBLY

54. REMOVE ENGINE REAR OIL SEAL RETAINER

55. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY

56. REMOVE REAR CRANKSHAFT OIL SEAL

57. REMOVE RING PIN

58. REMOVE STUD BOLT

1. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

1. Disconnect the sender gauge connector.

2. Remove the oil pressure sender gauge.

2. REMOVE OIL FILTER ELEMENT

1. Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

   Text in Illustration

   *1	Pipe
   *2	Hose

2. Remove the oil filter drain plug.

3. Install the pipe to the oil filter cap.

   Text in Illustration

   *1	Cap
   *2	Valve
   *3	Pipe
   *4	O-Ring
   *5	Hose

   NOTICE:

   If the O-ring is removed with the drain plug, install the O-ring together with the pipe.

   HINT:

   Use a container to catch the draining oil.

4. Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring as shown in the illustration.

5. Using SST, remove the oil filter cap.

   SST

   09228-06501

   Text in Illustration

   *1	Oil Filter Bracket Clip

   NOTICE:

   Do not remove the oil filter bracket clip.

6. Remove the oil filter element and O-ring from the oil filter cap.

   Text in Illustration

   *1	Oil Filter Element
   *2	O-Ring

   NOTICE:

   Be sure to remove the cap O-ring by hand, without using any tools, to prevent damage to the cap O-ring groove.

3. REMOVE NO. 1 OIL COOLER BRACKET

1. Remove the 2 nuts and bracket.

2. Disconnect the ground wire from the cylinder block.

4. REMOVE OIL FILTER BRACKET

1. Remove the 2 bolts, 2 nuts and filter bracket.

2. Remove the 2 O-rings.

5. REMOVE OIL FILLER CAP SUB-ASSEMBLY

6. REMOVE OIL FILLER CAP HOUSING

1. Remove the 2 bolts, filler cap housing and gasket.

7. REMOVE SPARK PLUG

1. Using a 16 mm plug wrench, remove the 8 spark plugs.

8. REMOVE VVT SENSOR

1. LH:

   Remove the 2 bolts and 2 VVT sensors.

2. RH:

   Remove the 2 bolts and 2 VVT sensors.

9. REMOVE CAMSHAFT POSITION SENSOR

1. Remove the bolt and camshaft position sensor.

10. REMOVE CRANK POSITION SENSOR PROTECTOR

1. Remove the 2 bolts and sensor protector.

11. REMOVE CRANKSHAFT POSITION SENSOR

1. Remove the bolt and crankshaft position sensor.

12. REMOVE CAMSHAFT OIL CONTROL VALVE ASSEMBLY

1. LH:

   Remove the 2 bolts and 2 oil control valves.

2. RH:

   Remove the 2 bolts and 2 oil control valves.

13. REMOVE WATER PUMP PULLEY

1. Using SST, hold the water pump pulley.

   SST

   09960-10010 (09962-01000,09963-01000)

2. Remove the 4 bolts and water pump pulley.

14. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

1. Remove the bolt and idler pulley.

15. REMOVE FLUID COUPLING BRACKET

1. Remove the 4 bolts and fluid coupling bracket.

16. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

1. Remove the standard bolt, 6 mm hexagon wrench bolt and belt tensioner.

17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

1. Remove the 14 bolts, seal washer, cylinder head cover and gasket.

   HINT:

   Make sure the removed parts are returned to the same places they were removed from.

2. Remove the 5 gaskets from the camshaft bearing caps (No. 2, No. 3).

18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH

1. Remove the bolt and noise filter.

2. Remove the 14 bolts, seal washer, cylinder head cover and gasket.

   HINT:

   Make sure the removed parts are returned to the same places they were removed from.

3. Remove the 5 gaskets from the camshaft bearing caps (No. 1, No. 3).

19. REMOVE OIL CONTROL VALVE FILTER

1. LH:

   Remove the 3 bolts, cylinder head cover spacer, gasket and filter.

   Text in Illustration

   *1	Cylinder Head Cover Spacer
   *2	Gasket
   *3	Filter

2. RH:

   Remove the 3 bolts, cylinder head cover spacer, gasket and filter.

   Text in Illustration

   *1	Cylinder Head Cover Spacer
   *2	Gasket
   *3	Filter

20. REMOVE SPARK PLUG TUBE GASKET

1. Bend the 4 ventilation baffle plate claws on the cylinder head cover to an angle of 90° or more.

2. Using a screwdriver, pry out the gaskets.

   Text in Illustration

   *1	Tape
   	Pry

   NOTICE:

   1. Be careful not to damage the cylinder head cover.
   2. Be careful not to damage the gasket when removing it, as the removed gasket needs to be used when installing a new one.

   HINT:

   Tape the screwdriver tip before use.

21. REMOVE CRANKSHAFT PULLEY

1. Using SST, loosen the crankshaft pulley set bolt until 2 or 3 threads are engaged.

   SST

   09213-70011 09330-00021

   Text in Illustration

   *a	Hold
   	Turn

2. Using the pulley set bolt and SST, remove the crankshaft pulley.

   SST

   09950-50013 (09951-05010,09952-05010,09953-05010,09954-05011)

   Text in Illustration

   *a	Hold
   	Turn

22. REMOVE WATER PUMP ASSEMBLY

1. Remove the 8 bolts, water pump and gasket.

23. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

1. Remove the 28 bolts and nut shown in the illustration.

   Text in Illustration

   	Bolt
   	Nut

2. Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver as shown in the illustration.

   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.

3. Remove the oil pump gasket from the cylinder block.

4. Remove the O-ring from the oil pan.

24. REMOVE WATER INLET PIPE

1. Remove the water inlet pipe.

2. Remove the 2 O-rings from the water inlet pipe.

25. REMOVE FRONT CRANKSHAFT OIL SEAL

1. Place the timing chain cover on wooden blocks.

2. Using a screwdriver and wooden block, pry out the oil seal.

   Text in Illustration

   *1	Wooden Block

   NOTICE:

   Do not damage the surface of the oil seal press fit hole.

   HINT:

   Tape the screwdriver tip before use.

26. SET NO. 1 CYLINDER TO TDC/COMPRESSION

1. Temporarily install the crankshaft pulley bolt.

2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.

   HINT:

   If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

   

   Text in Illustration

   *1	Timing Mark	*2	Timing Mark Position
   *3	Knock Pin Position	*4	Key
   *a	Toward Ceiling	*b	Approximately 2°
   *c	Approximately 45°	*d	Approximately 16°
   *e	Approximately 18°	*f	Approximately 32°

27. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH

1. Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

   Text in Illustration

   *1	Plunger
   *2	Stopper Plate

2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

   Text in Illustration

   *1	Plunger
   *2	Stopper Plate

3. Remove the 2 bolts, chain tensioner and gasket.

28. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

29. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH

1. Remove the 2 bolts and chain vibration damper.

30. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH

1. While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

   Text in Illustration

   *1	Pin
   *2	Plunger
   *a	Push

2. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

   Text in Illustration

   *a	Hold
   	Turn

   NOTICE:

   1. Be careful not to damage the cylinder head with the wrench.
   2. Do not disassemble the camshaft timing gear.

3. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

   Text in Illustration

   *a	Hold
   	Turn

   NOTICE:

   Be careful not to damage the cylinder head with the wrench.

4. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket LH.

5. Remove the No. 1 and No. 2 chains from the gears.

31. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

1. Remove the 2 bolts and chain tensioner.

32. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH

1. Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

   Text in Illustration

   *1	Plunger
   *2	Stopper Plate

2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

   Text in Illustration

   *1	Plunger
   *2	Stopper Plate

3. Remove the 2 bolts and chain tensioner.

33. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

34. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH

1. Remove the 2 bolts and vibration damper.

35. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH

1. While raising up the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

   Text in Illustration

   *1	Pin
   *2	Plunger
   *a	Push

2. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

   Text in Illustration

   *a	Hold
   	Turn

   NOTICE:

   1. Be careful not to damage the cylinder head with the wrench.
   2. Do not disassemble the camshaft timing gear.

3. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

   Text in Illustration

   *a	Hold
   	Turn

   NOTICE:

   Be careful not to damage the cylinder head with the wrench.

4. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket RH.

5. Remove the No. 1 and No. 2 chains from the gears.

36. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

1. Remove the 2 bolts and chain tensioner.

37. REMOVE CRANKSHAFT TIMING GEAR KEY

1. Using a screwdriver, remove the 2 timing gear keys from the crankshaft.

38. REMOVE CAMSHAFT BEARING CAP LH

1. Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

   Text in Illustration

   *1	IN
   *2	EX
   *3	Knock Pin

2. Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

3. Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

   NOTICE:

   Uniformly loosen the bolts while keeping the camshaft level.

4. Remove the 6 bearing caps.

   HINT:

   Arrange the removed parts in the correct order.

5. Remove the No. 3 and No. 4 camshafts.

39. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

1. Remove the camshaft housing by prying between the cylinder head and camshaft housing 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.

40. REMOVE CAMSHAFT BEARING CAP RH

1. Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

   Text in Illustration

   *1	EX
   *2	IN
   *3	Knock Pin

2. Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

3. Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

   NOTICE:

   Uniformly loosen the bolts while keeping the camshaft level.

4. Remove the 6 bearing caps.

   HINT:

   Arrange the removed parts in the correct order.

5. Remove the No. 1 and No. 2 camshafts.

41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

1. Remove the camshaft housing by prying between the cylinder head and camshaft housing 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.

42. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

1. Remove the 32 valve rocker arms from the cylinder heads.

   HINT:

   Arrange the removed parts in the correct order.

43. REMOVE VALVE LASH ADJUSTER ASSEMBLY

1. Remove the 32 valve lash adjusters from the cylinder heads.

   HINT:

   Arrange the removed parts in the correct order.

44. REMOVE VALVE STEM CAP

1. Remove the 32 valve stem caps from the cylinder heads.

   HINT:

   Arrange the removed parts in the correct order.

45. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

1. Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

2. Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

   NOTICE:

   1. Be careful not to drop washers into the cylinder head.
   2. Head warpage or cracking could result from removing bolts in an incorrect order.

   HINT:

   Be sure to arrange the removed parts for each installation position separately.

3. Remove the cylinder head and gasket.

46. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

1. Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

2. Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

   NOTICE:

   1. Be careful not to drop washers into the cylinder head.
   2. Head warpage or cracking could result from removing bolts in an incorrect order.

   HINT:

   Be sure to arrange the removed parts for each installation position separately.

3. Remove the cylinder head and gasket.

47. REMOVE CYLINDER BLOCK WATER JACKET SPACER

1. Remove the 2 water jacket spacers from the cylinder block.

   NOTICE:

   Be sure to remove the water jacket spacers. If not, they may fall and become damaged when the cylinder block is inverted.

48. REMOVE VENTILATION PIPE GASKET

1. Using a screwdriver, pry out the ventilation pipe gasket.

   HINT:

   Tape the screwdriver tip before use.

49. REMOVE NO. 1 HEAT EXCHANGER COVER

1. Remove the 12 bolts and 2 nuts.

   Text in Illustration

   	Bolt
   	Nut

2. Remove the heat exchanger by prying between the heat exchanger and cylinder block with a screwdriver.

   HINT:

   Tape the screwdriver tip before use.

50. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

1. Remove the 14 bolts and 2 nuts.

   Text in Illustration

   	Bolt
   	Nut

2. Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

   NOTICE:

   Be careful not to damage the contact surfaces of the oil pans.

51. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY

1. Remove the 14 bolts and 2 nuts.

   Text in Illustration

   	Bolt
   	Nut

   HINT:

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

2. Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.

   Text in Illustration

   *A	LH Side
   *B	RH Side

   NOTICE:

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

   HINT:

   Tape the screwdriver tip before use.

52. REMOVE NO. 1 OIL PAN BAFFLE PLATE

1. Remove the 7 bolts and baffle plate.

53. REMOVE OIL STRAINER SUB-ASSEMBLY

1. Remove the 2 bolts, oil strainer and O-ring.

54. REMOVE ENGINE REAR OIL SEAL RETAINER

1. Remove the 6 bolts and oil seal retainer.

2. Using a screwdriver, pry out the oil seal retainer.

   HINT:

   Tape the screwdriver tip before use.

55. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY

1. Remove the bolt and oil drain pipe.

2. Remove the O-ring.

56. REMOVE REAR CRANKSHAFT OIL SEAL

1. Place the oil seal retainer on wooden blocks.

   Text in Illustration

   *1	Wooden Block

2. Using a screwdriver and hammer, tap out the oil seal.

57. REMOVE RING PIN

NOTICE:

It is not necessary to remove the ring pin unless it is being replaced.

58. REMOVE STUD BOLT

NOTICE:

If the stud bolt is deformed or its threads are damaged, replace it.