Disassembly

2AZ-FXE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

(a) Remove the oil filler cap sub-assembly.

2. REMOVE OIL FILLER CAP GASKET

(a) Remove the oil filler cap gasket.

3. REMOVE VENTILATION VALVE SUB-ASSEMBLY

(a) Remove the ventilation valve sub-assembly.

4. REMOVE SPARK PLUG

(a) Remove the 4 spark plugs.

5. REMOVE OIL FILTER SUB-ASSEMBLY

(a) Using SST, remove the oil filter sub-assembly.

SST : 09228-06501

HINT
Place a container for oil to be drained before removing the oil filter.

6. REMOVE OIL COOLER ASSEMBLY

(a) Remove the oil filter union, plate washer, nut, oil cooler assembly and O-ring.

7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove the 8 bolts, 2 nuts and cylinder head cover sub-assembly.

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8. REMOVE CYLINDER HEAD COVER GASKET

(a) Remove the cylinder head cover gasket.

9. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the wire harness clamp.

(b) Separate the wire harness from the wire harness clamp bracket.

(c) Remove the 2 bolts and crankshaft position sensor.

10. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the bolt and camshaft position sensor.

11. REMOVE CRANKSHAFT PULLEY Removal

12. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Remove the bolt and camshaft timing oil control valve assembly.

(b) Remove the O-ring from the camshaft timing oil control valve assembly.

13. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Remove the 2 nuts, No. 1 chain tensioner assembly and gasket.

NOTICE:
Do not turn the crankshaft without the No. 1 chain tensioner assembly.

14. REMOVE WATER PUMP PULLEY Removal

15. REMOVE WATER PUMP ASSEMBLY Removal

16. REMOVE OIL PAN DRAIN PLUG

(a) Remove the oil pan drain plug and gasket.

17. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 12 bolts and 2 nuts.

Text in Illustration

(b) Insert the blade of an oil pan seal cutter between the crankcase, chain cover and oil pan, then cut through the applied sealer and remove the oil pan.

NOTICE:
Be careful not to damage the contact surfaces of the crankcase, chain cover or oil pan.

18. REMOVE IDLER PULLEY SUB-ASSEMBLY

(a) Remove the bolt, idler pulley cover plate and idler pulley sub-assembly.

19. REMOVE IDLER PULLEY BRACKET

(a) Remove the bolt, nut and idler pulley bracket.

20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

(a) Remove the 3 bolts and engine mounting bracket RH.

(b) Using an E10 "TORX" socket, remove the stud bolt for the V-ribbed belt tensioner.

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(d) Remove the timing chain cover by prying the portions between the timing chain cover, cylinder head and cylinder block with a screwdriver.

Text in Illustration

NOTICE:
Be careful not to damage the contact surfaces of the timing chain cover, cylinder head or cylinder block.

HINT
Tape the screwdriver tip before use.

21. REMOVE TIMING CHAIN CASE OIL SEAL

(a) Using a screwdriver and a hammer, remove the oil seal.

Text in Illustration

HINT
Tape the screwdriver tip before use.

22. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

(a) Remove the No. 1 crankshaft position sensor plate.

23. REMOVE TIMING CHAIN GUIDE

(a) Remove the bolt and timing chain guide.

24. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the bolt and chain tensioner slipper.

25. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and No. 1 chain vibration damper.

26. REMOVE CHAIN SUB-ASSEMBLY

(a) Remove the chain sub-assembly.

27. REMOVE CRANKSHAFT TIMING SPROCKET

(a) Remove the crankshaft timing sprocket.

28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft 90° counterclockwise to align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.

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(b) Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then remove the nut.

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(d) Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain.

29. REMOVE KEY

(a) Remove the 2 keys from the crankshaft.

30. REMOVE NO. 2 CAMSHAFT

(a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

(b) Remove the 5 bearing caps and No. 2 camshaft.

31. REMOVE CAMSHAFT

(a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

(b) Remove the 5 bearing caps and camshaft.

32. REMOVE NO. 1 CAMSHAFT BEARING

Remove the No. 1 camshaft bearing.

33. REMOVE NO. 2 CAMSHAFT BEARING

(a) Remove the No. 2 camshaft bearing.

34. REMOVE CAMSHAFT TIMING SPROCKET

(a) Clamp the camshaft in a vise.

(b) Remove the flange bolt and camshaft timing sprocket.

35. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY Removal

36. REMOVE CYLINDER HEAD SUB-ASSEMBLY Removal

37. REMOVE CYLINDER HEAD GASKET Removal

38. REMOVE CYLINDER BLOCK WATER JACKET SPACER

(a) Using needle-nose pliers, remove the cylinder block water jacket spacer.

NOTICE:
Be sure to remove the water jacket spacer if the cylinder block is to be turned upside down.

39. REMOVE UNION BOLT

(a) Remove the union bolt.

40. REMOVE OIL CONTROL VALVE FILTER

(a) Using an 8 mm socket hexagon wrench, remove the plug, gasket and oil control valve filter.

41. REMOVE OIL PUMP ASSEMBLY

(a) Remove the 3 bolts, oil pump assembly and gasket.

42. REMOVE NO. 1 AND NO. 2 BALANCESHAFT SUB-ASSEMBLY

(a) Uniformly loosen and remove the 8 bolts in the sequence shown in the illustration.

(b) Remove the balanceshaft housing.

(c) Remove the No. 1 and No. 2 balanceshafts.

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43. REMOVE NO. 1 BALANCESHAFT BEARING

(a) Remove the No. 1 balanceshaft bearings.

Text in Illustration

44. REMOVE ENGINE REAR OIL SEAL

(a) Using a knife, cut off the oil seal lip.

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(b) Using a screwdriver with its tip taped, pry out the oil seal.

NOTICE:
After removing the oil seal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper.

45. REMOVE STIFFENING CRANKCASE ASSEMBLY

(a) Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.

(b) Using a screwdriver with its tip wrapped with protective tape, remove the crankcase by prying between the crankcase and cylinder block.

Text in Illustration

NOTICE:
Be careful not to damage the contact surfaces of the crankcase or cylinder block.

(c) Remove the O-ring from the cylinder block.