Disassembly

2AZ-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

HINT
Check whether the engine is TMC made or not by referring to the following illustration.

Text in Illustration

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

(a) Remove the oil filler cap from the cylinder head cover.

2. REMOVE OIL FILLER CAP GASKET

(a) Remove the oil filler cap gasket from the oil filler cap.

3. REMOVE VENTILATION VALVE SUB-ASSEMBLY

(a) Using a 22 mm deep socket wrench, remove the ventilation valve from the cylinder head cover.

4. REMOVE SPARK PLUG Removal

5. REMOVE OIL FILTER SUB-ASSEMBLY Replacement

6. REMOVE OIL FILTER UNION

(a) Using a 12 mm socket hexagon wrench, remove the oil filter union.

7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove the 8 bolts and 2 nuts, remove the cylinder head cover.

Text in Illustration

8. REMOVE CYLINDER HEAD COVER GASKET

(a) Remove cylinder head cover gasket from the cylinder head cover.

9. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Removal

10. REMOVE CRANKSHAFT POSITION SENSOR (for TMC Made Engine)

(a) Disconnect the crankshaft position sensor wire from the rib portion of the timing chain cover.

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(b) Disengage the clamp and disconnect the crankshaft position sensor connector from the connector clamp bracket.

(c) Disconnect the crankshaft position sensor wire from the wire harness clamp bracket.

(d) Disengage the clamp and disconnect the crankshaft position sensor wire from the water pump.

(e) Remove the bolt and crankshaft position sensor.

11. REMOVE CRANKSHAFT POSITION SENSOR (except TMC Made Engine)

(a) Disengage the clamp and disconnect the crankshaft position sensor connector from the connector clamp bracket.

(b) Disconnect the crankshaft position sensor wire from the wire harness clamp bracket.

(c) Remove the bolt and crankshaft position sensor.

12. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the bolt and camshaft position sensor.

13. SET NO. 1 CYLINDER TO TDC / COMPRESSION Removal

14. REMOVE CRANKSHAFT PULLEY Removal

15. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Remove the bolt and camshaft timing oil control valve from the cylinder head.

NOTICE:
The camshaft timing oil control valve may be damaged when loosening the cylinder head bolt if the camshaft timing oil control valve is not removed.

16. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Removal

17. REMOVE WATER PUMP PULLEY Removal

18. REMOVE ENGINE WATER PUMP ASSEMBLY (for TMC Made Engine) Removal

19. REMOVE ENGINE WATER PUMP ASSEMBLY (except TMC Made Engine) Removal

20. REMOVE OIL PAN DRAIN PLUG

(a) Remove the oil pan drain plug from the oil pan.

21. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 12 bolts and 2 nuts.

Text in Illustration

(b) Insert the blade of 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 surface of the crankcase, chain cover and oil pan.

22. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Removal

23. REMOVE FRONT CRANKSHAFT OIL SEAL

(a) Using a screwdriver with its tip wrapped in protective tape, remove the oil seal.

NOTICE:
Be careful not to damage the timing chain case oil seal.

24. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE Removal

25. REMOVE TIMING CHAIN GUIDE Removal

26. REMOVE CHAIN TENSIONER SLIPPER Removal

27. REMOVE NO. 1 CHAIN VIBRATION DAMPER Removal

28. REMOVE CHAIN SUB-ASSEMBLY

29. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET Removal

30. REMOVE NO. 2 CHAIN SUB-ASSEMBLY Removal

31. REMOVE NO. 2 CAMSHAFT

(a) Using several steps, uniformly loosen and remove the No. 2 and 4 No. 3 bearing caps in the sequence shown in the illustration.

NOTICE:
Uniformly loosen the bolts while keeping the camshaft level.

HINT
Arrange the removed parts in the correct order.

Text in Illustration

(b) Remove the No. 2 camshaft.

32. REMOVE CAMSHAFT

(a) Using several steps, uniformly loosen and remove the No. 1 and 4 No. 3 bearing caps in the sequence shown in the illustration.

NOTICE:
Uniformly loosen the bolts while keeping the camshaft level.

HINT
Arrange the removed parts in the correct order.

Text in Illustration

(b) Remove the camshaft.

33. REMOVE NO. 1 CAMSHAFT BEARING

(a) Remove the camshaft bearing from the No. 1 camshaft bearing cap.

34. REMOVE NO. 2 CAMSHAFT BEARING

(a) Remove the No. 2 camshaft bearing from the cylinder head.

35. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET

(a) Clamp the camshaft in a vise, and make sure that the camshaft timing gear or sprocket does not rotate.

NOTICE:
* Do not overtighten the vise.
* Do not damage the camshaft.

(b) Remove the bolt and camshaft timing gear or sprocket.

36. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY Removal

37. REMOVE CYLINDER HEAD SUB-ASSEMBLY Removal

38. REMOVE CYLINDER HEAD GASKET

39. REMOVE CYLINDER BLOCK WATER JACKET SPACER (for TMC Made Engine)

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

NOTICE:
Before turning the cylinder block upside down, make sure that the water jacket spacer is removed, as it will fall out.

40. REMOVE CYLINDER BLOCK WATER JACKET SPACER (except TMC Made Engine)

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

NOTICE:
Before turning the cylinder block upside down, make sure that the water jacket spacer is removed, as it will fall out.

41. REMOVE INLET WATER HOUSING DRAIN COCK ASSEMBLY (except TMC Made Engine)

(a) Remove the plug from the drain cock.

Text in Illustration

(b) Remove the drain cock from the inlet water housing.

42. REMOVE INLET WATER HOUSING (except TMC Made Engine)

(a) Using a E5 "TORX" socket wrench, remove the 6 stud bolts from the inlet water housing.

(b) Using several steps, uniformly loosen and remove the 5 bolts and inlet water housing in the sequence shown in the illustration.

43. REMOVE OIL CONTROL VALVE FILTER

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

Text in Illustration

44. REMOVE NO. 1 TAPER HEAD SCREW PLUG

(a) Remove the No. 1 taper head screw plug.

45. REMOVE OIL PUMP ASSEMBLY Removal

46. INSPECT BALANCESHAFT THRUST CLEARANCE Engine Unit

47. INSPECT BALANCESHAFT OIL CLEARANCE Engine Unit

48. REMOVE NO. 1 AND NO. 2 BALANCESHAFTS

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

Text in Illustration

49. REMOVE NO. 1 BALANCESHAFT BEARING

(a) Remove the 8 No. 1 balanceshaft bearings in the shown in the illustration.

Text in Illustration

50. REMOVE REAR CRANKSHAFT OIL SEAL Removal

51. REMOVE STIFFENING CRANKCASE ASSEMBLY

(a) Using several steps, uniformly loosen and remove the 11 bolts and in the sequence shown in the illustration.

(b) Remove the crankcase by prying the portions between the crankcase and cylinder block.

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

Text in Illustration

HINT
Tape the screwdriver tip before use.

(c) Remove the O-ring.