Disassembly

2ZR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

1. REMOVE ENGINE HANGER

(a) Remove the 2 bolts and 2 engine hangers.

2. REMOVE OIL FILLER CAP SUB-ASSEMBLY

(a) Remove the oil filler cap.

3. REMOVE OIL FILLER CAP GASKET

(a) Remove the oil filler cap gasket.

4. REMOVE SPARK PLUG

(a) Using a 14 mm socket wrench, remove the 4 spark plugs.

5. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the 2 bolts and 2 sensors.

6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Remove the 2 bolts, 2 O-rings, bracket and 2 oil control valves.

7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove the 13 bolts, seal washer and cylinder head cover.

(b) Remove the 3 gaskets from the camshaft bearing cap.

NOTICE:
When removing the cylinder head cover, some of the gaskets may stick to it so be careful not to drop any of the gaskets into the engine.

8. REMOVE CYLINDER HEAD COVER GASKET

(a) Remove the cylinder head cover gasket.

9. SET NO. 1 CYLINDER TO TDC / COMPRESSION

(a) Turn the crankshaft pulley, and align its timing notch with the "0" timing mark on the timing chain cover sub-assembly.

(b) Check that timing marks on both the camshaft timing exhaust gear and camshaft timing gear are facing upward, as shown in the illustration.

HINT
If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

10. REMOVE CRANKSHAFT PULLEY

(a) Using SST, hold the pulley in place and loosen the pulley bolt.

SST : 09213-58013

91651-60855

SST : 09330-00021

(b) Using SST, remove the pulley bolt and pulley.

SST : 09950-50013

09951-05010

09952-05010

09953-05020

09954-05021

11. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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

NOTICE:
Do not turn the crankshaft after you have removed the chain tensioner.

12. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the bolt and crankshaft position sensor.

13. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.

14. REMOVE NO. 1 TAPER SCREW PLUG

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

15. REMOVE KNOCK SENSOR

(a) Remove the bolt and knock sensor.

16. REMOVE ENGINE WATER TEMPERATURE SENSOR

(a) Using a 19 mm deep socket wrench, remove the engine water temperature sensor.

(b) Remove the gasket from the engine water temperature sensor.

17. REMOVE OIL FILTER SUB-ASSEMBLY

(a) Using SST, remove the oil filter cap.

SST : 09228-06501

HINT
Use a container to catch the draining oil. After the oil filter cap is loosened approximately 4 turns and the cap rib is facing straight down, engine oil will begin to drain from the gap between the oil filter cap and oil pan.

(b) Remove the oil filter element and O-ring from the oil filter cap.

NOTICE:
Be sure to remove the O-ring (for the cap) by hand, without using any tools, to prevent damage to the O-ring groove on the cap.

18. REMOVE WATER INLET

(a) Remove the 2 nuts and remove the water inlet.

19. REMOVE THERMOSTAT

(a) Remove the thermostat from the cylinder block.

(b) Remove the gasket from the thermostat.

20. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

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

(b) Remove the 4 bolts and remove the oil filter bracket.

(d) Remove the 19 bolts.

(e) Remove the timing chain or belt cover sub-assembly by prying between the timing chain or belt cover sub-assembly and cylinder head or cylinder block with a screwdriver wrapped in protective tape.

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

(f) Remove the 3 O-rings from the cylinder head and cylinder block.

(g) Remove the 3 bolts and the engine water pump assembly.

(h) Remove the gasket from the timing chain or belt cover sub-assembly.

21. REMOVE WATER INLET HOUSING

(a) Remove the 3 bolts, gasket and water inlet housing.

22. REMOVE NO. 1 GENERATOR BRACKET

(a) Remove the 4 bolts and generator bracket.

23. REMOVE NO. 2 CHAIN VIBRATION DAMPER

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

24. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the chain tensioner slipper from the cylinder block.

25. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and the chain vibration damper.

26. REMOVE CHAIN SUB-ASSEMBLY

(a) Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to loosen the chain on the camshaft timing gears.

(b) With the chain loosened, release the chain from the camshaft timing gear assembly and rest it on the camshaft timing gear assembly.

HINT
Be sure to release the chain from the sprocket completely.

(c) Turn the camshaft clockwise to return it to the original position and remove the chain.

27. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

(a) Remove the crankshaft timing gear or sprocket.

28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

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

(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.

(d) Remove the oil pump drive shaft gear, oil pump drive gear and chain.

29. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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

30. REMOVE CRANKSHAFT TIMING GEAR KEY

(a) Using a screwdriver, remove the 2 crankshaft timing gear keys.

HINT
Tape the screwdriver tip before use.

31. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

(a) Check the lock of the camshaft timing gear.

(b) Release the lock pin.

NOTICE:
Before removing the camshaft timing gear assembly, make sure that the lock pin has been released.

(1) After cleaning and degreasing the VVT oil hole on the intake side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

NOTICE:
Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

(2) Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A)

(3) Apply approximately 150 kPa (1.5 kgf/ cm2, 22 psi) of air pressure to the hole pricked in procedure A to release the lock pin.

NOTICE:
* If air leaks out, reattach the adhesive tape.
* Cover the oil hole with a shop rag or piece of cloth when applying air pressure to prevent oil from spraying.
* Do not lock the camshaft timing gear assembly. If it is locked, release the lock pin again.

HINT
* The camshaft timing gear assembly may be turned in the advance direction without applying any force.
* If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

(4) Remove the adhesive tape from the No. 1 camshaft bearing cap.

(c) Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing gear assembly.

NOTICE:
* Before removing the camshaft timing gear, make sure that the lock pin has been released.
* Be sure not to remove the other 4 bolts.
* Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.

32. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

(a) Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing exhaust gear assembly.

NOTICE:
* Be sure not to remove the other 4 bolts.
* Keep the camshaft timing exhaust gear assembly horizontal while removing it from the camshaft.

33. REMOVE CAMSHAFT BEARING CAP

(a) Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

(b) Uniformly loosen and remove the 15 bearing cap bolts in the sequence shown in the illustration.

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

(c) Remove the 5 bearing caps.

HINT
Arrange the removed parts in the correct order.

(d) Remove the camshaft and No. 2 camshaft.

34. REMOVE CAMSHAFT

(a) Remove the camshaft.

35. REMOVE NO. 2 CAMSHAFT

(a) Remove the No. 2 camshaft.

36. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

(a) Remove the 16 valve rocker arms.

HINT
Arrange the removed parts in the correct order.

37. 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.

38. REMOVE OIL CONTROL VALVE FILTER

(a) Remove the oil control valve filter.

39. REMOVE NO. 1 CAMSHAFT BEARING

(a) Remove the 2 No. 1 camshaft bearings.

HINT
Arrange the removed parts in the correct order.

40. REMOVE NO. 2 CAMSHAFT BEARING

(a) Remove the 2 No. 2 camshaft bearings.

HINT
Arrange the removed parts in the correct order.

41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

(a) Remove the 2 bolts.

(b) Remove the camshaft housing by prying between the cylinder head and camshaft housing 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.

42. REMOVE CYLINDER HEAD SUB-ASSEMBLY

(a) Using several steps, loosen and remove the 10 cylinder head bolts uniformly with a 10 mm bi-hexagon wrench in the sequence shown in the illustration.

Remove the 10 cylinder head bolts and the plate washers.

NOTICE:
* Do not drop the washers into the cylinder head.
* Head warpage or cracking could result from removing bolts in the wrong order.

(b) Remove the cylinder head sub-assembly.

43. REMOVE CYLINDER HEAD GASKET

44. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Remove the water drain cock plug from the water drain cock assembly.

(b) Remove the water drain cock assembly from the cylinder block.

45. REMOVE VENTILATION VALVE SUB-ASSEMBLY

(a) Remove the ventilation valve.

46. REMOVE OIL PAN DRAIN PLUG

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

47. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 10 bolts and 2 nuts.

(b) Install the blade of oil pan seal cutter between the No. 2 oil pan sub-assembly and stiffening crankcase assembly, and cut off the applied sealer and remove the No. 2 oil pan sub-assembly.

NOTICE:
Do not damage the No. 2 oil pan sub-assembly or stiffening crankcase assembly.

48. REMOVE OIL PUMP ASSEMBLY

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

49. REMOVE STIFFENING CRANKCASE ASSEMBLY

(a) Remove the 11 bolts.

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

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