Part 1

2UZ-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

Part 1

DISASSEMBLY

HINT:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets, O-rings and oil seals with new ones.

1. REMOVE ENGINE HANGERS

(a) Remove the 4 bolts and engine hangers.
2. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Remove the 2 water drain cocks.
3. REMOVE SPARK PLUG
4. REMOVE OIL FILLER CAP SUB-ASSEMBLY
5. REMOVE OIL FILLER CAP HOUSING

(a) Remove the 2 nuts and oil filler cap housing.
6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.
7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

(a) Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.
8. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Remove the pulley bolt, cover plate and idler pulley.
9. REMOVE NO. 2 TIMING BELT COVER SUB-ASSEMBLY

(a) Remove the 2 bolts and timing belt cover.
10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

(a) Remove the bolt, 2 nuts and belt tensioner.
11. REMOVE FAN BRACKET SUB-ASSEMBLY

(a) Remove the 2 bolts, 2 nuts and fan bracket.
12. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

(a) Using SST, remove the pulley bolt.
SST: 09213-70011
SST: 09330-00021

(b) Using SST, remove the crankshaft pulley.
SST: 09950-50013
09951-05010
09952-05010
09953-05010
09953-05020
09954-05021
13. REMOVE NO. 1 TIMING BELT COVER

(a) Remove the 4 bolts and timing belt cover.
14. REMOVE TIMING GEAR COVER SPACER

(a) Remove the cover spacer and gasket.
15. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

(a) Remove No. 1 crankshaft position sensor plate.
16. SET NO. 1 CYLINDER TO TDC / COMPRESSION

(a) If reusing the timing belt, check the installation marks on the timing belt.
(1) Check that there are 3 installation marks on the timing belt by turning the crankshaft as shown in the illustration.
If the installation marks have disappeared, put a new installation mark on the timing belt before removing each part.

(b) Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.

(c) Check that the timing marks of the camshaft timing pulleys and timing belt plates are aligned.
If not, turn the crankshaft 1 complete revolution (360°).
17. REMOVE TIMING BELT

(a) Set the No. 1 cylinder to approx. 45° BTDC/compression.
(1) Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approx. 45°.

NOTE: If the timing belt is disengaged, having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft timing pulley and camshaft, causing damage. So always set the crankshaft pulley at the correct angle.

(b) Alternately loosen the 2 bolts, then remove the bolts, chain tensioner and dust boot.

(c) Using SST, loosen the tension between the camshaft timing pulley (RH bank) and crankshaft timing pulley by slightly turning the camshaft timing pulley (RH bank) counterclockwise.
SST: 09960-10010
09962-01000
09963-00350
(d) Disconnect the timing belt from the No. 1 timing belt idler and remove the timing belt.
18. REMOVE CAMSHAFT TIMING PULLEYS

(a) Hold the crankshaft with a wrench, and remove the 8 bolts and 2 timing pulleys.
19. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

(a) Using a 10 mm hexagon wrench, remove the bolt, idler and plate washer.
20. REMOVE NO. 2 TIMING BELT IDLER SUB-ASSEMBLY

(a) Remove the bolt and idler.
21. REMOVE CRANKSHAFT TIMING PULLEY

(a) Using SST, remove the timing pulley.
SST: 09950-50013
09951-05010
09952-05010
09953-05010
09953-05020
09954-05011

NOTE: Do not turn the timing pulley.

22. REMOVE NO. 2 REAR TIMING BELT PLATE RH
(a) Remove the 2 bolts and No. 2 rear timing belt plate RH.
23. REMOVE REAR TIMING BELT PLATE RH
(a) Remove the bolt, stud bolt and rear timing belt plate RH.
24. REMOVE NO. 2 REAR TIMING BELT PLATE LH
(a) Remove the 2 bolts and No. 2 rear timing belt plate LH.
25. REMOVE REAR TIMING BELT PLATE LH
(a) Remove the bolt and rear timing belt plate LH.
26. REMOVE CAMSHAFTS

NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

(a) Remove the camshafts of the RH bank.

(1) In order to install a service bolt to the sub and main gears, turn the camshaft with a wrench. The hexagonal portion of the camshaft is used for turning the camshaft with the wrench.
(2) Secure the sub-gear to the main gear with a service bolt.

Recommended service bolt:

HINT: When removing the camshafts, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.

(3) Set the timing mark (1-dot mark) of the camshaft main gear at approx. 10° angle by turning the hexagonal portion of the exhaust camshaft with a wrench.

(4) Uniformly loosen the 22 bearing cap bolts in the order shown in the illustration, then remove all the bolts.
(5) Remove the oil feed pipe, 9 bearing caps, oil control valve filter, camshaft housing plug and 2 camshafts.
(b) Remove the camshafts on the LH bank.

HINT: When removing the camshaft, make sure that the torsional spring force of the sub-gear has eliminated by the above operation.

(3) Align the timing marks (2-dot marks) of the camshaft drive and driven gears by turning the hexagonal portion of the exhaust camshaft with a wrench.

(a) Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several steps, in the order shown in the illustration. Likewise, loosen the 10 bolts on the other side. Remove the 20 cylinder head bolts and plate washers.

NOTICE:
- Cylinder head warpage or cracking may result from removing bolts in incorrect order.
- Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

(b) Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench.

NOTICE:
- Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
- The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.

HINT: If the cylinder head cannot be lifted easily, pry between the cylinder head and cylinder block with a screwdriver.

29. REMOVE WATER PUMP ASSEMBLY

(a) Remove the 5 bolts, 2 stud bolts, nut, water pump and gasket.
30. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 17 bolts and 2 nuts.
(b) Insert the blade of oil pan seal cutter between the oil pan and No. 2 oil pan, and cut off applied sealer. Remove the No. 2 oil pan.

NOTICE:
- Be careful not to damage the contact surface of the oil pan and the No. 2 oil pan.
- Be careful not to damage the No. 2 oil pan flange.

31. REMOVE OIL PAN BAFFLE PLATE NO.1

(a) Remove the 2 bolts, 2 nuts and baffle plate.
32. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 18 bolts and 2 nuts.

(b) Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block in the order shown in the illustration.

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

33. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the 2 bolts, 2 nuts, oil strainer and gasket.
34. REMOVE OIL PUMP ASSEMBLY

(a) Remove the 7 bolts and stud bolt.

HINT: Use a 6 mm hexagon wrench to tighten the hexagon head bolt.

(b) Using a screwdriver, remove the oil pump by prying the portions between the oil pump and cylinder block.

NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pump.

(c) Remove the O-ring from the cylinder block.
35. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 7 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and crankshaft bearing cap.
(c) Remove the O-ring.

Continued in Part 2 Part 2