Lexus ES: Disassembly

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / 2gr-fks (engine Mechanical) / Engine Unit / Disassembly

DISASSEMBLY

PROCEDURE

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

(a) Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly LH.

(b) Remove the oil filler cap gasket from the oil filler cap sub-assembly.

2. REMOVE SPARK PLUG

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3. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

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4. REMOVE TAPER SCREW PLUG (w/ Taper Screw Plug)

(a) Remove the taper screw plug from the cylinder block sub-assembly.

5. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Remove the cylinder block water drain cock plug from the cylinder block water drain cock sub-assembly.

(b) Remove the cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.

6. REMOVE CRANKSHAFT PULLEY

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7. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH

(a) Remove the 7 bolts and front No. 1 engine mounting bracket LH from the timing chain cover assembly.

8. REMOVE WATER BY-PASS HOSE

(a) Slide the 2 clips and remove the water by-pass hose from the water inlet pipe and water inlet with thermostat sub-assembly.

9. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

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10. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)

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11. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)

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12. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)

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13. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)

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14. REMOVE VVT SENSOR (for Intake Side of Bank 1)

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15. REMOVE VVT SENSOR (for Exhaust Side of Bank 1)

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16. REMOVE VVT SENSOR (for Intake Side of Bank 2)

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17. REMOVE VVT SENSOR (for Exhaust Side of Bank 2)

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18. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR

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19. REMOVE CRANKSHAFT POSITION SENSOR

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20. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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21. REMOVE WATER OUTLET

(a) w/ Stud Bolt:

	Bolt
	Bolt or Nut

(1) Remove the 4 bolts, 2 nuts and water outlet from the cylinder head sub-assembly and cylinder head LH.

(b) w/o Stud Bolt:

(1) Remove the 6 bolts and water outlet from the cylinder head sub-assembly and cylinder head LH.

22. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Type A

(1) Remove the 2 clips and No. 1 engine cover sub-assembly from the cylinder head cover sub-assembly.

(b) Type B

(1) Remove the clip and No. 1 engine cover sub-assembly from the cylinder head cover sub-assembly.

(d) Remove the camshaft bearing cap oil hole gasket from the camshaft bearing cap.

(e) Remove the 3 cylinder head cover gaskets from the cylinder head cover sub-assembly.

23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Remove the No. 1 V-bank cover bracket from the cylinder head cover sub-assembly LH.

(b) Remove the 14 bolts and cylinder head cover sub-assembly LH from the camshaft housing sub-assembly LH.

(d) Remove the 3 No. 2 cylinder head cover gaskets from the cylinder head cover sub-assembly LH.

24. REMOVE SPARK PLUG TUBE GASKET

(a) Using a screwdriver as shown in the illustration, deform each spark plug tube gasket inwards and remove the 6 spark plug tube gaskets from the cylinder head cover sub-assembly and cylinder head cover sub-assembly LH.

*a	Protective Tape

25. REMOVE OIL PAN DRAIN PLUG

(a) Remove the oil pan drain plug and oil pan drain plug gasket from the No. 2 oil pan sub-assembly.

26. REMOVE OIL FILTER CAP ASSEMBLY

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27. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

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28. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 15 bolts and 2 nuts from the No. 2 oil pan sub-assembly.

(b) Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and No. 2 oil pan sub-assembly. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

NOTICE:

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

29. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the 2 nuts and oil strainer sub-assembly from the timing chain cover assembly.

(b) Remove the oil strainer gasket from the oil strainer sub-assembly.

30. REMOVE ENGINE OIL LEVEL SENSOR

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31. REMOVE OIL PAN SUB-ASSEMBLY

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32. REMOVE OIL FILTER BRACKET CLIP

(a) Remove the oil filter bracket clip from the oil pan sub-assembly.

33. REMOVE NO. 1 OIL PAN BAFFLE PLATE

(a) Remove the 8 bolts and No. 1 oil pan baffle plate from the crankshaft bearing cap set bolt.

34. REMOVE TIMING CHAIN COVER PLATE

(a) Remove the 4 bolts, timing chain cover plate and timing chain cover gasket from the timing chain cover assembly.

35. REMOVE TIMING CHAIN CASE OIL SEAL

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36. REMOVE TIMING CHAIN COVER ASSEMBLY

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37. REMOVE ENGINE WATER PUMP ASSEMBLY

(a) Remove the 7 bolts, engine water pump assembly and water pump gasket from the timing chain cover assembly.

38. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

(a) Temporarily tighten the crankshaft pulley set bolt to the crankshaft.

(b) Turn the crankshaft clockwise to align the timing mark of the crankshaft timing sprocket key groove chase position with the center line of the block bore (for Bank 1) (TDC / compression).

*a	Center Line
*b	Key Groove

(c) Check that the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are aligned with the timing marks of the camshaft bearing caps as shown in the illustration.

Timing Mark

Viewpoint

NOTICE:

Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear assembly and each camshaft timing exhaust gear assembly.
If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

HINT:

If not aligned, turn the crankshaft 1 revolution (360°) clockwise and align the timing marks as shown in the illustration.
For the camshaft or No. 3 camshaft sub-assembly:
Be sure to check the mark (A) at the point where the marks (B), (C) and (D) are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

39. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Turn the stopper plate clockwise to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.

*a	Plunger
*b	Stopper Plate
*c	Pin

(b) Turn the stopper plate counterclockwise to set the lock, and insert a 1.0 mm (0.0394 in.) diameter pin into the hole of the stopper plate.

40. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the chain tensioner slipper from the cylinder block sub-assembly.

41. REMOVE CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft 10° counterclockwise to loosen the chain sub-assembly of the crankshaft timing sprocket.

*a	Center Line
*b	Mark
*c	Key Groove

(b) Remove the crankshaft pulley set bolt from the crankshaft.

(d) Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) so that it is positioned as shown in the illustration.

NOTICE:

Be sure to loosen the chain sub-assembly between the banks.

*A	for Bank 1

(e) Remove the chain sub-assembly from the engine assembly.

42. REMOVE IDLE SPROCKET ASSEMBLY

(a) Using a 10 mm hexagon socket wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft from the cylinder block sub-assembly.

43. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and No. 1 chain vibration damper from the cylinder head LH and cylinder block sub-assembly.

44. REMOVE NO. 2 CHAIN VIBRATION DAMPER

(a) Remove the 2 No. 2 chain vibration dampers from the cylinder head LH and cylinder head sub-assembly.

45. REMOVE CRANKSHAFT TIMING SPROCKET

(a) Remove the crankshaft timing sprocket from the crankshaft.

46. REMOVE CRANKSHAFT TIMING GEAR KEY

(a) Remove the 2 crankshaft timing gear keys from the crankshaft.

47. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)

(a) While raising the No. 2 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the hole to secure the No. 2 chain tensioner assembly.

*a	Pin
*b	Plunger
	Push

(b) Using a wrench to hold the hexagonal portion of camshaft, loosen the camshaft timing gear bolt of the camshaft timing gear assembly.

NOTICE:

Be careful not to damage the camshaft, camshaft housing sub-assembly or spark plug tube with wrench.
Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.
If the camshaft timing gear bolt has been struck or dropped, replace it.

*a	Hold
	Turn

(c) Using a wrench to hold the hexagonal portion of No. 2 camshaft, loosen the camshaft timing gear bolt of the camshaft timing exhaust gear assembly.

NOTICE:

Be careful not to damage the No. 2 camshaft, camshaft housing sub-assembly or spark plug tube with wrench.
Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.
If the camshaft timing gear bolt has been struck or dropped, replace it.

*a	Hold
	Turn

(d) Remove the 2 camshaft timing gear bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly together with the No. 2 chain sub-assembly.

48. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt and No. 2 chain tensioner assembly from the camshaft housing sub-assembly.

49. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

(a) Check that the camshaft and No. 2 camshaft are positioned as shown in the illustration.

*a	Straight Pin
*b	Front View
*c	45°

(b) Uniformly loosen and remove the 9 bolts in several steps in the order shown in the illustration.

NOTICE:

Make sure that the camshaft and No. 2 camshaft remain level while uniformly loosening the bolts.

(d) Remove the fuel pump lifter housing from the camshaft housing sub-assembly.

(e) Remove the 5 camshaft bearing caps from the camshaft housing sub-assembly.

(f) Remove the 2 oil control valve filters from the 2 camshaft bearing caps.

50. REMOVE CAMSHAFT

(a) Remove the camshaft from the camshaft housing sub-assembly.

51. REMOVE NO. 2 CAMSHAFT

(a) Remove the No. 2 camshaft from the camshaft housing sub-assembly.

52. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

(a) Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver with its tip wrapped with protective tape.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head sub-assembly and camshaft housing sub-assembly.

*a	Protective Tape

53. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)

(a) While pushing down the No. 3 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the hole to secure the No. 3 chain tensioner assembly.

*a	Pin
*b	Plunger
	Push

(b) Using a wrench to hold the hexagonal portion of No. 3 camshaft sub-assembly, loosen the camshaft timing gear bolt of the camshaft timing gear assembly.

*a	Hold
	Turn

NOTICE:

Be careful not to damage the No. 3 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with wrench.
Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.
If the camshaft timing gear bolt has been struck or dropped, replace it.

(c) Using a wrench to hold the hexagonal portion of No. 4 camshaft sub-assembly, loosen the camshaft timing gear bolt of the camshaft timing exhaust gear assembly.

NOTICE:

Be careful not to damage the No. 4 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with wrench.
Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.
If the camshaft timing gear bolt has been struck or dropped, replace it.

*a	Hold
	Turn

(d) Remove the 2 camshaft timing gear bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly together with the No. 2 chain sub-assembly.

54. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt and No. 3 chain tensioner assembly from the camshaft housing sub-assembly LH.

55. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

(a) Check that the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly are positioned as shown in the illustration.

*a	Straight Pin
*b	Front View

(b) Uniformly loosen and remove the 8 bolts in several steps in the order shown in the illustration.

NOTICE:

Make sure that the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly remain level while uniformly loosening the bolts.

(d) Remove the 5 camshaft bearing caps from the camshaft housing sub-assembly LH.

(e) Remove the 2 oil control valve filters from the 2 camshaft bearing caps.

56. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

(a) Remove the No. 3 camshaft sub-assembly from the camshaft housing sub-assembly LH.

57. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

(a) Remove the No. 4 camshaft sub-assembly from the camshaft housing sub-assembly LH.

58. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

(a) Remove the camshaft housing sub-assembly LH by prying between the cylinder head LH and camshaft housing sub-assembly LH with a screwdriver with its tip wrapped with protective tape.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head LH and camshaft housing sub-assembly LH.

*a	Protective Tape

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

(a) Remove the 24 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly and cylinder head LH.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

60. REMOVE VALVE LASH ADJUSTER ASSEMBLY

(a) Remove the 24 valve lash adjuster assemblies from the cylinder head sub-assembly and cylinder head LH.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

61. REMOVE VALVE STEM CAP

(a) Remove the 24 valve stem caps from the cylinder head sub-assembly and cylinder head LH.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

62. REMOVE SENSOR WIRE

(a) Remove the 3 bolts and sensor wire from the cylinder head LH and cylinder block sub-assembly.

63. REMOVE REAR ENGINE OIL SEAL RETAINER

(a) Remove the 6 bolts from the rear engine oil seal retainer.

(b) Using a screwdriver with its tip wrapped with protective tape, pry out the rear engine oil seal retainer.

*a	Protective Tape
	Pry

NOTICE:

Be careful not to damage the rear engine oil seal retainer.

64. REMOVE REAR ENGINE OIL SEAL

(a) Place the rear engine oil seal retainer on wooden blocks.

*a	Protective Tape
*b	Wooden Block

(b) Using a hammer and a screwdriver with its tip wrapped with protective tape, tap out the rear engine oil seal.

NOTICE:

Be careful not to damage the rear engine oil seal retainer.

65. REMOVE CYLINDER HEAD SUB-ASSEMBLY

(a) Using a 10 mm bi-hexagon socket wrench, uniformly loosen the 8 cylinder head set bolts in the order shown in the illustration. Remove the 8 cylinder head set bolts and 8 cylinder head set plate washers.

NOTICE:

Be careful not to drop the cylinder head set plate washers into the cylinder head sub-assembly.
Warpage or cracking of the cylinder head sub-assembly may result from removing the cylinder head set bolts in the incorrect order.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

(b) Remove the cylinder head sub-assembly from the cylinder block sub-assembly.

66. REMOVE CYLINDER HEAD GASKET

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67. REMOVE CYLINDER HEAD LH

(a) Uniformly loosen and remove the 2 bolts in several steps in the order shown in the illustration.

(b) Using a 10 mm bi-hexagon socket wrench, uniformly loosen the 8 cylinder head set bolts in the order shown in the illustration. Remove the 8 cylinder head set bolts and 8 cylinder head set plate washers.

NOTICE:

Be careful not to drop the cylinder head set plate washers into the cylinder head LH.
Warpage or cracking of the cylinder head LH may result from removing the cylinder head set bolts in the incorrect order.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

68. REMOVE NO. 2 CYLINDER HEAD GASKET

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69. REMOVE WATER INLET PIPE

(a) Remove the 2 bolts and water inlet pipe from the cylinder block sub-assembly.

70. REMOVE STRAIGHT PIN

NOTICE:

It is not necessary to remove the straight pins unless they are being replaced.

71. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN

NOTICE:

It is not necessary to remove the camshaft bearing cap setting ring pins unless they are being replaced.

72. REMOVE STUD BOLT

NOTICE:

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

SEE MORE:

Problem Symptoms Table

PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of problem symptoms. If multiple suspected areas are listed, the potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspect

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Lexus ES: Disassembly

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Problem Symptoms Table

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