2AR-FE ENGINE MECHANICAL  ENGINE UNIT  DISASSEMBLY  

1.REMOVE ENGINE COVER JOINT

a.

Remove the 3 engine cover joints.

19100P 2.REMOVE SPARK PLUG

11101J 3.REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)

4.REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)

11102A 5.REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

6.REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

12108 7.REMOVE OIL FILLER CAP SUB-ASSEMBLY

11301K 8.REMOVE CRANKSHAFT POSITION SENSOR

12204 9.REMOVE PCV VALVE

12205 10.REMOVE PCV CASE

a.

Remove the 8 bolts and 2 nuts.

b.

Remove the PCV case by prying between the PCV case and cylinder block with a screwdriver.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder block and PCV case.

HINT:

Tape the screwdriver tip before use.

12215 11.REMOVE SEPARATOR CASE

a.

Remove the 2 bolts, separator case and gasket.

16268 12.REMOVE NO. 1 WATER BY-PASS PIPE

a.

Remove the bolt, 2 nuts, water by-pass pipe and gasket.

16321 13.REMOVE WATER INLET

16331A 14.REMOVE THERMOSTAT

16620 15.REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

16100 16.REMOVE ENGINE WATER PUMP ASSEMBLY

15710 17.REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler)

16323 18.REMOVE WATER INLET HOUSING

a.

Remove the 4 bolts, nut, water inlet housing and gasket.

13471 19.REMOVE CRANKSHAFT PULLEY

a.

1.25,0.823 0.844,0.479 0.844,0.479 1.469,0.844 true 0.51,0.365 0.833,0.552 0.323,0.188 10 SST 0.854,1.677 1.052,1.865 0.198,0.188 10 *b 2.271,1.677 2.469,1.865 0.198,0.188 10 *a

SST

*b

*a

*a	Turn
*b	Hold

Using SST, hold the crankshaft pulley and loosen the pulley bolt until 2 or 3 threads are screwed into the crankshaft.

SST

09213-54015  
09330-00021  

HINT:

Part number of installation bolt for SST (crankshaft pulley holdingtool): 91551-80650 (quantity: 2)

b.

2.333,0.25 2.479,0.25 2.479,0.25 2.563,0.677 false 1.469,1.188 1.469,1.021 1.469,1.021 1.844,0.833 true 0.969,1.698 1.104,1.698 1.104,1.698 1.365,2.385 false 1.354,1.208 1.75,1.396 0.396,0.188 10 false SST 2.115,0.156 2.354,0.333 0.24,0.177 10 false *1 0.615,1.604 0.938,1.792 0.323,0.188 10 false SST

SST

*1

SST

*1	Pulley Bolt

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

SST

09950-50013  (09954-05011, 09951-05010, 09952-05010, 09953-05020)

HINT:

Apply lubricant to the threads and end of SST.

11201 20.REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

11193 21.REMOVE SPARK PLUG TUBE GASKET

12315A 22.REMOVE ENGINE MOUNTING BRACKET RH

11310 23.REMOVE TIMING CHAIN COVER ASSEMBLY

24.REMOVE TIMING CHAIN COVER TIGHT PLUG

a.

Using a 14 mm hexagon wrench, remove the plug and gasket.

11324 25.REMOVE TIMING CHAIN COVER PLATE

11301C 26.REMOVE TIMING CHAIN COVER OIL SEAL

27.SET NO. 1 CYLINDER TO TDC/COMPRESSION

13566B 28.REMOVE TIMING CHAIN GUIDE

13540 29.REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

13559 30.REMOVE CHAIN TENSIONER SLIPPER

13506 31.REMOVE CHAIN SUB-ASSEMBLY

13561 32.REMOVE NO. 1 CHAIN VIBRATION DAMPER

13521 33.REMOVE CRANKSHAFT TIMING SPROCKET

a.

Remove the crankshaft timing sprocket from the crankshaft.

13050 34.REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

13070A 35.REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

11103 36.REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

37.REMOVE CAMSHAFT BEARING CAP

15678A 38.REMOVE OIL CONTROL VALVE FILTER

a.

Remove the oil control valve filter from the No. 1 camshaft bearing cap.

13511 39.REMOVE CAMSHAFT

11811 40.REMOVE NO. 1 CAMSHAFT BEARING

a.

Remove the No. 1 camshaft bearing.

11821 41.REMOVE NO. 2 CAMSHAFT BEARING

a.

Remove the No. 2 camshaft bearing.

42.REMOVE CAMSHAFT HOUSING STUD BOLT

11151A 43.REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

11114A 44.REMOVE CAMSHAFT HOUSING STRAIGHT PIN

13801 45.REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

13750 46.REMOVE VALVE LASH ADJUSTER ASSEMBLY

13716 47.REMOVE VALVE STEM CAP

11101 48.REMOVE CYLINDER HEAD SUB-ASSEMBLY

11115 49.REMOVE CYLINDER HEAD GASKET

11445 50.REMOVE CYLINDER BLOCK WATER JACKET SPACER

a.

Remove the cylinder block water jacket spacer from the cylinder block.

NOTICE:

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

51.REMOVE OIL FILTER ELEMENT

12101 52.REMOVE OIL PAN SUB-ASSEMBLY

a.

Remove the 11 bolts and 2 nuts.

b.

Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut off the applied sealer and remove the oil pan sub-assembly.

NOTICE:

·

Be careful not to damage the contact surfaces of the stiffening crankcase assembly and oil pan sub-assembly.

·

Be careful not to damage the stiffening crankcase flange.

15104 53.REMOVE OIL STRAINER SUB-ASSEMBLY

a.

Remove the 3 bolts, oil strainer sub-assembly and gasket.

12121 54.REMOVE NO. 1 OIL PAN BAFFLE PLATE

a.

Remove the 5 bolts and No. 1 oil pan baffle plate.

13411 55.INSPECT CRANKSHAFT BACKLASH

a.

Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.

Standard backlash:

0.05 to 0.20 mm (0.00197 to 0.00787 in.)

Maximum backlash:

0.20 mm (0.00787 in.)

If the backlash is more than the maximum, replace the engine balancer assembly.

13620B 56.REMOVE ENGINE BALANCER ASSEMBLY

a.

Remove the 7 bolts and engine balancer assembly.

NOTICE:

Do not disassemble the engine balancer assembly.

57.INSPECT BALANCE SHAFT THRUST CLEARANCE

11420 58.REMOVE STIFFENING CRANKCASE ASSEMBLY

a.

Remove the 7 bolts.

b.

0.052,0.052 0.302,0.25 0.25,0.198 10 *a 0.052,2.135 0.281,2.313 0.229,0.177 10 *b

*a

*b

*a	LH Side
*b	RH Side

Using a screwdriver, remove the stiffening crankcase by prying between the stiffening crankcase and cylinder block at the places shown in the illustration.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder block and stiffening crankcase.

HINT:

Tape the screwdriver tip before use.

59.REMOVE STIFFENING CRANKCASE STUD BOLT

60.REMOVE STIFFENING CRANKCASE RING PIN

11401L 61.REMOVE REAR ENGINE OIL SEAL

a.

Remove the rear engine oil seal from the cylinder block.