Disassembly
2ZR-FXE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY
1. REMOVE OIL FILLER CAP SUB-ASSEMBLY
(a) Remove the oil filler cap.
2. REMOVE OIL FILLER CAP GASKET
(a) Remove the oil filler cap gasket.
3. REMOVE ENGINE COVER JOINT BOLT
(a) Remove the 3 engine cover joint bolts.
4. REMOVE WIRING HARNESS CLAMP BRACKET
(a) Remove the bolt and wiring harness clamp bracket.
5. REMOVE SPARK PLUG Removal
6. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and camshaft position sensor.
7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Remove the bolt and camshaft timing oil control valve.
(b) Remove the O-ring from the camshaft timing oil control valve.
8. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the bolt and crankshaft position sensor.
9. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
10. REMOVE KNOCK SENSOR
(a) Remove the bolt and knock sensor.
11. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a) Remove the engine coolant temperature sensor and gasket.
12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove the 13 bolts, seal washer and cylinder head cover.
NOTICE:
As the gaskets may stick to the cylinder head cover, be careful not to drop any of the gaskets into the engine when removing the cylinder head cover.
(b) Remove the 2 gaskets from the camshaft bearing cap.
13. REMOVE CYLINDER HEAD COVER GASKET
(a) Remove the cylinder head cover gasket.
14. REMOVE SPARK PLUG TUBE GASKET
(a) Pry up the 4 claws of the ventilation baffle plate.
NOTICE:
Do not deform the claws of the baffle plate more than necessary.
(b) Remove the 4 gaskets from the cylinder head cover.
HINT
Prevent the plug tube gaskets from being deformed as much as possible. The removed gaskets will be used when installing new gaskets.
NOTICE:
Be careful not to damage the cylinder head cover.
15. REMOVE OIL FILTER CAP ASSEMBLY Replacement
16. REMOVE INLET WATER SUB-ASSEMBLY
(a) Remove the bolt, 2 nuts, inlet water sub-assembly and gasket.
17. REMOVE INLET WATER SUB-ASSEMBLY STUD BOLT
NOTICE:
If a stud bolt is deformed or its threads are damaged, replace it.
18. SET NO. 1 CYLINDER TO TDC/COMPRESSION Removal
19. REMOVE CRANKSHAFT PULLEY Removal
20. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Removal
21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal
22. REMOVE TIMING CHAIN COVER OIL SEAL Removal
23. REMOVE CHAIN TENSIONER SLIPPER Removal
24. REMOVE NO. 1 CHAIN VIBRATION DAMPER Removal
25. REMOVE NO. 2 CHAIN VIBRATION DAMPER Removal
26. REMOVE CHAIN SUB-ASSEMBLY Removal
27. REMOVE CRANKSHAFT TIMING SPROCKET Removal
28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY Removal
29. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE
(a) Remove the crankshaft position sensor plate.
30. REMOVE CRANKSHAFT TIMING GEAR KEY
(a) Using a screwdriver, remove the 2 crankshaft timing gear keys.
Text in Illustration
HINT
Tape the screwdriver tip before use.
31. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY Removal
32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY Removal
33. REMOVE CAMSHAFT TIMING SPROCKET Removal
34. REMOVE CAMSHAFT BEARING CAP Removal
35. REMOVE CAMSHAFT Removal
36. REMOVE NO. 2 CAMSHAFT Removal
37. REMOVE CAMSHAFT HOUSING STRAIGHT PIN
NOTICE:
It is not necessary to remove a straight pin unless it is being replaced.
38. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Remove the 16 valve rocker arms.
HINT
Arrange the removed parts in the correct order.
39. REMOVE VALVE LASH ADJUSTER ASSEMBLY
(a) Remove the 16 valve lash adjusters from the cylinder head.
HINT
Arrange the removed parts in the correct order.
40. REMOVE VALVE STEM CAP
(a) Remove the 16 valve stem caps.
HINT
Arrange the removed parts in the correct order.
41. REMOVE OIL CONTROL VALVE FILTER
(a) Remove the oil control valve filter from the No. 1 camshaft bearing cap.
42. REMOVE NO. 1 CAMSHAFT BEARING
(a) Remove the 2 camshaft bearings.
43. REMOVE NO. 2 CAMSHAFT BEARING
(a) Remove the 2 camshaft bearings.
44. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY Removal
45. REMOVE CYLINDER HEAD SUB-ASSEMBLY Removal
46. REMOVE CYLINDER HEAD GASKET Removal
47. REMOVE VENTILATION VALVE SUB-ASSEMBLY
(a) Remove the ventilation valve sub-assembly.
48. REMOVE OIL PAN DRAIN PLUG
(a) Remove the drain plug and gasket.
49. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY Removal
50. REMOVE OIL PUMP ASSEMBLY Removal
51. REMOVE STIFFENING CRANKCASE ASSEMBLY
(a) Uniformly loosen and remove the 11 bolts.
(b) Using a screwdriver, remove the stiffening crankcase by prying between the stiffening crankcase and cylinder block.
Text in Illustration
HINT
Tape the screwdriver tip before use.
NOTICE:
Be careful not to damage the contact surfaces of the crankcase and cylinder block.
52. REMOVE NO. 1 TAPER SCREW PLUG
(a) Remove the 2 No. 1 taper screw plugs.
53. REMOVE STIFFENING CRANKCASE STUD BOLT
NOTICE:
If a stud bolt is deformed or its threads are damaged, replace it.
54. REMOVE STIFFENING CRANKCASE RING PIN
NOTICE:
It is not necessary to remove a ring pin unless it is being replaced.
55. REMOVE ENGINE REAR OIL SEAL
(a) Remove the engine rear oil seal from the cylinder block.
