Part 2
PARTIAL ENGINE ASSY (1NZ-FXE)
OVERHAUL
21. REMOVE FUEL DELIVERY PIPE SUB-ASSY
a. Remove the 3 bolts and fuel delivery pipe with fuel injector assembly.
b. Remove the delivery pipe spacer No. 1 from the cylinder head.
22. REMOVE FUEL INJECTOR ASSY
a. Remove the fuel injector assembly from the fuel delivery pipe.
23. REMOVE NO.2 CAMSHAFT
NOTICE: When rotating the camshaft with the chain removed, rotate the crankshaft counterclockwise by 40° from the TDC/compression.
a. Remove the camshaft bearing caps No. 1 and No. 2 in the sequence shown in the illustration, then remove the camshaft No. 2.
NOTICE: Uniformly loosen the bolts keeping the camshaft level.
24. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET
a. Clamp the camshaft in a vise (using an aluminum protector).
b. Remove the bolt and camshaft timing gear.
NOTICE: Be careful not to damage the camshaft.
25. REMOVE CAMSHAFT
a. Remove the camshaft bearing caps No. 2 in the sequence shown in the illustration, then remove the camshaft.
NOTICE: Uniformly loosen the blots keeping the camshaft level.
26. INSPECT CAMSHAFT TIMING GEAR ASSY
a. Check the lock of the camshaft timing gear.
1. Clamp the hexagonal lobe of the camshaft in a vise (using an aluminum protector).
2. Check that the camshaft timing gear is locked.
NOTICE: Be careful not to damage the camshaft.
b. Release the lock pin.
1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
HINT: One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the 2 oil paths for each groove with rubber pieces before wrapping the cam journal with the tape.
2. Punctuate the tape which covers the advance side path and retard side path on the opposite side.
3. Apply approximately 150 kPa (1.5 kgf/cm2) of air pressure into the 2 punctuated paths (the advance side path and retard side path).
NOTICE: When applying air pressure, cover the paths with a shop rag to prevent oil splash.
4. Confirm that the camshaft timing gear assembly revolves in the advance direction when reducing the air pressure of the retard side path.
HINT: The lock pin is released and the camshaft timing gear revolves in the advance direction.
5. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure of the retard side path, then release the air pressure of the advance side path.
NOTICE: If the air pressure of the advance side path is released first, the camshaft timing gear assembly occasionally shifts in the retard direction abruptly, which may damage the lock pin. Be sure to release the air pressure of the retard side path first.
c. Check the smooth revolution.
1. Let the camshaft timing gear assembly rotate by 2 or 3 revolutions in the movable range (22.5°) except the most retarded position. Check that it rotates smoothly.
NOTICE: Do the check by hand, and do not use air pressure.
d. Check the lock at the most retarded position.
1. Confirm that the camshaft timing gear assembly is locked at the most retarded position (at the end of the movable range).
27. REMOVE CAMSHAFT TIMING GEAR ASSY
a. Turn the camshaft timing gear assembly at the most advanced position.
b. Remove the bolt and camshaft timing gear assembly.
NOTICE:
^ Do not remove the 4 other bolts.
^ If reusing the camshaft timing gear assembly, unlock the lock pin inside the camshaft timing gear first.
28. REMOVE CYLINDER HEAD SUB-ASSY
a. Using several steps, loosen the 10 cylinder head bolts with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Then remove the 10 bolts and 10 washers.
NOTICE:
^ When removing the bolt, do not drop the washer into the engine.
^ Removing the cylinder head bolts in a wrong order may cause damage to the cylinder head.
29. REMOVE CYLINDER HEAD GASKET
30. REMOVE OIL FILTER UNION
a. Using a 12 mm socket hexagon wrench, remove the oil filter union.
31. REMOVE OIL PAN SUB-ASSY NO.2
a. Remove the oil pan drain plug and gasket.
b. Remove the 9 bolts and 2 nuts.
c. Insert the blade of SST between the oil pan and oil pan No.2, and cut off the applied sealer and remove the oil pan No.2.
SST 09032-00100
NOTICE: Be careful not to damage the oil pan and oil pan No.2.
32. REMOVE OIL STRAINER SUB-ASSY
a. Remove the bolt and 2 nuts, then remove the oil strainer and gasket.
33. REMOVE OIL PAN SUB-ASSY
a. Remove the 13 bolts.
b. Using a screwdriver with its tip wrapped in tape, remove the oil pan by prying out between the cylinder block and oil pan as illustrated.
NOTICE: Do not forcibly pry out between the cylinder block and oil pan.
c. Remove the 2 O-rings from the cylinder block.
d. Using a Torx socket wrench E5, remove the 4 stud bolts.
34. REMOVE ENGINE REAR OIL SEAL
a. Remove the engine rear oil seal.
35. INSPECT CHAIN SUB-ASSY
a. Using a spring scale, measure the length of the timing chain when it was pulled with 140 N (14.3 kgf, 31 lb).
Maximum chain length: 124.2 mm (4.890 inch)
If the chain length is greater than maximum, replace the chain.
HINT: Measure the length at least at 3 places to obtain the average length.
36. INSPECT CHAIN TENSIONER ASSY NO.1
a. Check that the plunger moves smoothly when the cam is raised with your finger.
b. Release the cam. Check that the plunger is locked by the cam and does not move when it is pushed by your finger.
37. INSPECT CAMSHAFT TIMING GEAR ASSY
a. Wrap the chain around the timing gear.
b. Using vernier calipers, measure the diameter of the timing gear with the chain wrapped.
Minimum gear diameter (w/ chain): 96.2 mm (3.787 inch)
If the diameter is less than minimum, replace the camshaft timing gear assembly.
NOTICE: When measuring the diameter, vernier calipers must contact the chain link.
38. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
a. Wrap the chain around the timing gear.
b. Using vernier calipers, measure the diameter of the timing gear with the chain wrapped.
Minimum gear diameter (w/ chain): 96.2 mm (3.787 inch)
If the diameter is less than minimum, replace the camshaft timing gear.
NOTICE: When measuring the diameter, vernier calipers must contact the chain link.
39. INSPECT CHAIN TENSIONER SLIPPER
a. Using vernier calipers, measure the thickness of the chain tensioner slipper.
Maximum wear: 1.0 mm (0.039 inch)
If the thickness is greater than maximum, replace the chain tensioner slipper.
40. INSPECT CHAIN VIBRATION DAMPER NO.1
a. Using vernier calipers, measure the thickness of the chain vibration damper.
Maximum wear: 1.0 mm (0.039 inch)
If the thickness is greater than maximum, replace the chain vibration damper.