Disassembly

2AZ-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

DISASSEMBLY

1. REMOVE SPARK PLUG
2. REMOVE OIL FILLER CAP SUB-ASSEMBLY
3. REMOVE OIL FILLER CAP GASKET
4. REMOVE VENTILATION VALVE SUB-ASSEMBLY
5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Removal

6. REMOVE CYLINDER HEAD COVER GASKET
7. REMOVE OIL FILTER SUB-ASSEMBLY Replacement

8. REMOVE OIL FILTER UNION
(a) Using a 12 mm socket hexagon wrench, remove the oil filter union.
9. REMOVE CAMSHAFT POSITION SENSOR Removal

10. REMOVE CRANKSHAFT POSITION SENSOR Removal

11. REMOVE WATER PUMP PULLEY Removal

12. REMOVE WATER PUMP ASSEMBLY Removal

13. REMOVE OIL PAN DRAIN PLUG
(a) Remove the oil pan drain plug and gasket.
14. REMOVE OIL PAN SUB-ASSEMBLY Removal

15. REMOVE CRANKSHAFT PULLEY Removal

16. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Removal

17. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal

18. REMOVE TIMING CHAIN COVER OIL SEAL Replacement

19. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE
20. REMOVE TIMING CHAIN GUIDE Removal

21. REMOVE CHAIN TENSIONER SLIPPER Removal

22. REMOVE CHAIN SUB-ASSEMBLY
23. REMOVE NO. 1 CHAIN VIBRATION DAMPER Removal

24. REMOVE CRANKSHAFT TIMING SPROCKET
25. REMOVE NO. 2 CHAIN SUB-ASSEMBLY Removal

26. REMOVE OIL PUMP DRIVE GEAR
27. REMOVE OIL PUMP ASSEMBLY Removal

28. REMOVE CAMSHAFT






(a) Using several steps, uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration.
(b) Remove the 10 bearing caps, then remove the camshaft and No. 2 camshaft.
29. REMOVE CYLINDER HEAD SUB-ASSEMBLY Removal

30. REMOVE CYLINDER HEAD GASKET
31. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
32. REMOVE OIL CONTROL VALVE FILTER






(a) Using a 6 mm socket hexagon wrench, remove the plug and gasket.
(b) Remove the oil control valve filter.
33. REMOVE NO. 1 TAPER SCREW PLUG






(a) Remove the plug from the cylinder block.
34. INSPECT BALANCE SHAFT THRUST CLEARANCE






(a) Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
Standard thrust clearance:
0.05 to 0.09 mm (0.0020 to 0.0035 in.)
Maximum thrust clearance:
0.09 mm (0.0035 in.)
If the thrust clearance is greater than the maximum, replace the balance shaft housing and bearings. If necessary, replace the balance shaft.
35. INSPECT BALANCE SHAFT OIL CLEARANCE






(a) Using several steps, uniformly loosen and remove the 8 bolts in the sequence shown in the illustration.
(b) Remove the balance shaft housing from the crankcase.
HINT: Keep the lower bearing and balance shaft housing together.

(c) Lift out the No. 1 and No. 2 balance shafts.
HINT: Keep the upper bearing with the crankcase.

(d) Clean each bearing and journal.
(e) Check each bearing and journal for pitting and scratches.
If a bearing or journal is damaged, replace the bearings. If necessary, replace the balance shaft.
(f) Place the No. 1 and No. 2 balance shafts onto the crankcase.






(g) Lay a strip of Plastigage across each journal.
(h) Install the balance shaft housing.
(i) Apply a light coat of engine oil on the threads and under the heads of the bolts.






(j) Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
Torque: 21.6 Nm (220 kgf-cm, 16 ft-lbf)






(k) Mark the front of the bolts with paint.
(l) Retighten the bolts 90° as shown in the illustration.
(m) Check that the paint mark is now at a 90° angle to the front.
(n) Remove the balance shaft housing from the crankcase.
(o) Measure the Plastigage at its widest point.
Standard oil clearance:
0.004 to 0.049 mm (0.0002 to 0.0019 in.)
Maximum oil clearance:
0.049 mm (0.0019 in.)
NOTE: Remove the Plastigage completely after the measurement.
If the oil clearance is greater than the maximum, replace the bearing. If necessary, replace the balance shaft.
HINT: If replacing a bearing, select a new one with the same number.

Standard balance shaft housing journal bore diameter:






Standard balance shaft journal diameter:
22.985 to 23.000 mm (0.9049 to 0.9055 in.)
Standard bearing center wall thickness:






36. REMOVE BALANCE SHAFT
37. REMOVE NO. 1 BALANCE SHAFT BEARING
38. REMOVE ENGINE REAR OIL SEAL






(a) Using a knife, cut off the lip of the oil seal.
(b) Using a screwdriver with its tip wrapped with tape, pry out the oil seal.
NOTE: After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.

39. REMOVE STIFFENING CRANKCASE ASSEMBLY






(a) Using several steps, uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.
(b) Remove the crankcase by prying the portions between the crankcase and cylinder block.
NOTE: Be careful not to damage the contact surfaces of the crankcase and cylinder bock.

(c) Remove the O-ring from the cylinder block.
40. INSPECT CONNECTING ROD THRUST CLEARANCE






(a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance:
0.160 to 0.362 mm (0.0063 to 0.0143 in.)
Maximum thrust clearance:
0.362 mm (0.0143 in.)
If the thrust clearance is greater than the maximum, replace the connecting rod. If necessary, replace the crankshaft.
41. INSPECT CONNECTING ROD OIL CLEARANCE
NOTE: Do not turn the crankshaft during the measurement.

(a) Using marking paint, write the matched cylinder number on each connecting rod and cap.
HINT: The matchmarks in the connecting rods and caps are for ensuring correct reassembly.





(b) Using a 12 mm socket wrench, remove the 2 bolts and connecting rod cap.
(c) Clean the crank pin and bearing.
(d) Check the crank pin and bearing for pitting and scratches.






(e) Lay a strip of Plastigage on the crank pin.
(f) Check that the front mark of the connecting rod cap is facing in the correct direction.
(g) Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
(h) Using a 12 mm socket wrench, tighten the bolts in several passes to the specified torque.
Torque: 24.5 Nm (250 kgf-cm, 18 ft-lbf)






(i) Mark the front of the connecting rod bolts with paint.
(j) Retighten the cap bolts 90° as shown in the illustration.
(k) Check that the crankshaft turns smoothly.
(l) Using a 12 mm socket wrench, remove the 2 bolts and connecting rod cap.
(m) Measure the Plastigage at its widest point.
Standard oil clearance:
0.024 to 0.048 mm (0.0009 to 0.0019 in.)
Maximum oil clearance:
0.08 mm (0.0032 in.)
NOTE: Remove the Plastigage completely after the measurement.
If the oil clearance is greater than the maximum, replace the connecting rod bearing. If necessary, grind or replace the crankshaft.
HINT: If replacing a bearing, select a new one with the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.

Standard connecting rod large end bore diameter:






Standard connecting rod bearing thickness:






Standard crankshaft pin diameter:






42. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD






(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(b) 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.

43. REMOVE CONNECTING ROD BEARING
44. REMOVE PISTON RING SET






(a) Using a piston ring expander, remove the 2 compression rings.
(b) Remove the 2 side rails and expander by hand.
45. REMOVE PISTON PIN HOLE SNAP RING






(a) Using a small screwdriver, pry out the 2 snap rings.
46. REMOVE PISTON






(a) Gradually heat the piston up to 80 to 90°C (176 to 194°F).






(b) Using a plastic hammer and brass bar, lightly tap out the piston pin, then remove the connecting rod.
- The piston and pin are a matched set.
- Arrange the piston, pin, ring, connecting rod and bearings in the correct order.

47. INSPECT CRANKSHAFT THRUST CLEARANCE






(a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.04 to 0.24 mm (0.0016 to 0.0095 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set.
HINT: The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.).

48. INSPECT CRANKSHAFT OIL CLEARANCE
NOTE: Do not turn the crankshaft during the measurement.

(a) Clean each main journal and bearing.
(b) Check each main journal and bearing for pitting and scratches.






(c) Install the upper bearing with an oil groove onto the cylinder block.
NOTE: Do not apply engine oil to the bearing or its contact surface.





(d) Install the lower bearing onto the bearing cap.
NOTE: Do not apply engine oil to the bearing or its contact surface.

(e) Place the crankshaft onto the cylinder block.






(f) Lay a strip of Plastigage across each journal.






(g) Examine the front marks and numbers and install the bearing caps onto the cylinder block in the order shown in the illustration.
(h) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.






(i) Using several steps, uniformly install and tighten the 10 bearing cap bolts in the sequence shown in the illustration.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)






(j) Mark the front of the bearing cap bolts with paint.
(k) Retighten the 10 bearing cap bolts by 90°.
(l) Check that the paint marks are at a 90° angle to the front.
(m) Remove the bearing caps.
(n) Measure the Plastigage at its widest point.
Standard oil clearance:
0.017 to 0.040 mm (0.0007 to 0.0016 in.)
Maximum oil clearance:
0.050 mm (0.0020 in.)
NOTE: Remove the Plastigage completely after the measurement.
If the oil clearance is greater than the maximum, replace the crankshaft bearing. If necessary, replace the crankshaft.
HINT: If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft. Then select a new bearing with the calculated number. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.





EXAMPLE
- Imprinted number on the cylinder block is 3.
- Imprinted number on the crankshaft is 4. 3 + 4 = 7
Select the bearing marked "7".
Standard cylinder block journal bore diameter:






Standard crankshaft journal diameter:






Standard bearing center wall thickness:






49. REMOVE CRANKSHAFT






(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 from the cylinder block.
(c) Remove the crankshaft from the cylinder block.
50. REMOVE CRANKSHAFT THRUST WASHER UPPER
51. REMOVE CRANKSHAFT BEARING
HINT: Arrange the bearings in the correct order.

52. REMOVE NO. 2 CRANKSHAFT BEARING
HINT: Arrange the bearings in the correct order.

53. REMOVE STUD BOLT
(a) Remove the 8 stud bolts.