Page 897 of 3000

EM–922GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(c) Uniformly loosen and remove the 13 bearing cap
bolts in the sequence shown in the illustration.
NOTICE:
Uniformly loosen the bolts while keeping the
camshaft level.
(d) Remove the 5 bearing caps.
46. REMOVE NO. 3 CAMSHAFT
(a) Remove the No. 3 camshaft.
47. REMOVE NO. 4 CAMSHAFT
(a) Remove the No. 4 camshaft.
48. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH
(a) Remove the camshaft housing sub-assembly LH by
prying between the cylinder head and camshaft
housing sub-assembly LH 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.
49. REMOVE NO. 1 VALVE ROCKER ARM SUB-
ASSEMBLY
(a) Remove the 24 No. 1 valve rocker arm sub-
assemblies.
HINT:
Arrange the removed parts in the correct order.
50. REMOVE VALVE LASH ADJUSTER ASSEMBLY
(a) Remove the 24 valve lash adjuster assemblies from
the cylinder head.
HINT:
Arrange the removed parts in the correct order.
51. 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.
NOTICE:
• Be careful not to drop washers into the
cylinder head.
• Cylinder head warpage or cracking could
result from removing bolts in an incorrect
order.
HINT:
Be sure to keep separate the removed parts for
each installation position.
(b) Remove the cylinder head sub-assembly RH and
cylinder head gasket.
A129708E01
A129709E01
A129712E01
Page 898 of 3000
2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–93
EM
52. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH
(a) Uniformly loosen and remove the cylinder head set
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.
NOTICE:
• Be careful not to drop washers into the
cylinder head.
• Cylinder head warpage or cracking could
result from removing bolts in an incorrect
order.
HINT:
Be sure to keep separate the removed parts for
each installation position.
(c) Remove the cylinder head sub-assembly LH and
No. 2 cylinder head gasket.
53. REMOVE WATER INLET PIPE
(a) Remove 2 clamps and separate the No. 1 water by-
pass hose.
(b) Remove the 2 bolts and water inlet pipe.
54. REMOVE VALVE STEM CAP
(a) Remove the valve stem caps from the cylinder
heads.
HINT:
Arrange the removed parts in the correct order.
A129710E01
A129711E01
A162635
Page 899 of 3000
EM–942GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
55. REMOVE INTAKE VALVE
(a) Using SST, compress the inner compression spring
and remove the valve spring retainer locks.
SST 09202-70020 (09202-00010)
(b) Remove the valve spring retainer, inner
compression spring and intake valve.
HINT:
Arrange the removed parts in the correct order.
56. REMOVE EXHAUST VALVE
(a) Using SST, compress the inner compression spring
and remove the valve spring retainer locks.
SST 09202-70020 (09202-00010)
(b) Remove the valve spring retainer, inner
compression spring and exhaust valve.
HINT:
Arrange the removed parts in the correct order.
57. REMOVE VALVE STEM OIL SEAL
(a) Using needle-nose pliers, remove the valve stem oil
seals.
58. REMOVE VALVE SPRING SEAT
(a) Using compressed air and a magnetic finger,
remove the valve spring seats by blowing air onto
them.
A129714E01
A129715E01
A120701E01
A120702E01
Page 900 of 3000
2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–95
EM
59. REMOVE NO. 1 STRAIGHT SCREW PLUG
(a) Using a 10 mm hexagon wrench, remove the 4 No.
1 straight screw plugs and 4 gaskets.
NOTICE:
If water leaks from the straight screw plug or the
plug corrodes, replace it.
60. REMOVE NO. 2 STRAIGHT SCREW PLUG
(a) Using a 14 mm hexagon wrench, remove the 2 No.
2 straight screw plugs and 2 gaskets.
NOTICE:
If water leaks from the straight screw plug or the
plug corrodes, replace it.
61. REMOVE RING PIN
NOTICE:
It is not necessary to remove the ring pin unless it is
being replaced.
62. REMOVE STUD BOLT
NOTICE:
If the stud bolt is deformed or the threads are
damaged, replace it.
63. REMOVE STRAIGHT PIN
NOTICE:
If the straight pin is deformed or the threads are
damaged, replace it.
64. 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.
A129718E04
A129719E04
Page 901 of 3000

EM–962GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(c) Using SST and a hammer, tap out the intake valve
guide bushes.
SST 09201-10000 (09201-01050), 09950-70010
(09951-07100)
65. 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 exhaust valve
guide bushes.
SST 09201-10000 (09201-01050), 09950-70010
(09951-07100)
66. REMOVE PISTON SUB-ASSEMBLY WITH
CONNECTING ROD
(a) Check that the matchmarks on the connecting rod
sub-assembly and connecting rod cap are aligned.
HINT:
The matchmarks on the connecting rod sub-
assembly and connecting rod cap 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.
A121839E02
A120709E02
A129760E01
A129761
Page 902 of 3000
2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–97
EM
(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.
67. REMOVE CONNECTING ROD BEARING
HINT:
Arrange the removed parts in the correct order.
68. REMOVE CRANKSHAFT
(a) Uniformly loosen and remove the 8 crankshaft
bearing cap bolts and seal washers in several steps
and in the sequence shown in the illustration.
(b) Uniformly loosen the 16 crankshaft bearing cap
bolts, in several steps and in the sequence shown in
the illustration.
A129720E01
A129721E03
A134892E01
Page 903 of 3000

EM–982GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(c) Using a screwdriver, pry out the main bearing caps.
Remove the 4 crankshaft bearing caps and lower
crankshaft 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 surface of
the cylinder block and the main bearing cap.
(d) Remove the crankshaft.
69. REMOVE CRANKSHAFT BEARING
(a) Remove the upper crankshaft bearing and lower
crankshaft bearing.
HINT:
Arrange the removed parts in the correct order.
70. REMOVE CRANKSHAFT THRUST WASHER SET
(a) Remove the upper crankshaft bearings and upper
crankshaft thrust washers from the cylinder block
sub-assembly.
71. 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.
72. 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.
A122567E01
A109726
A129724E01
A129725
Page 904 of 3000
2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–99
EM
(b) Disconnect the connecting rod from the piston.
(1) Using a screwdriver, pry off the piston pin hole
snap rings from the piston.
(2) Gradually heat the piston to approximately
80
C (176F).
(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.
(c) Using a gasket scraper, remove the carbon from the
piston top.
(d) Using a groove cleaning tool or broken ring, clean
the piston ring grooves.
A129726
A109729E02
A129728
A129729
A129730