Disassembly

2AZ-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

(a) Remove the oil filler cap.
2. REMOVE OIL FILLER CAP GASKET

(a) Remove the oil filler cap gasket.
3. REMOVE VENTILATION VALVE SUB-ASSEMBLY

(a) Remove the ventilation valve.
4. REMOVE SPARK PLUG

(a) Remove the spark plugs.
5. REMOVE OIL FILTER SUB-ASSEMBLY

(a) Using SST, remove the oil filter.
SST: 09228-06501
HINT: Place a container for oil to be drained into before removing the oil filter.

6. REMOVE OIL FILTER UNION (w/o Oil Cooler)

(a) Using a 12 mm hexagon wrench, remove the union.
7. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler)

(a) Remove the oil filter union, plate washer, nut, oil cooler and O-ring.
(b) Remove the union bolt.
8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Removal
9. REMOVE CYLINDER HEAD COVER GASKET

(a) Remove the cylinder head cover gasket.
10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Removal
11. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the wire harness clamp.
(b) Separate the wire harness from the wire harness clamp bracket.

(a) Remove the bolt and sensor.
13. REMOVE CRANKSHAFT PULLEY Removal
14. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Removal
15. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Removal
16. REMOVE WATER PUMP PULLEY Removal
17. REMOVE WATER PUMP ASSEMBLY Removal
18. REMOVE OIL PAN DRAIN PLUG

(a) Remove the oil pan drain plug and gasket.
19. REMOVE OIL PAN SUB-ASSEMBLY Removal
20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal
21. REMOVE TIMING CHAIN CASE OIL SEAL

(a) Using a screwdriver and a hammer, remove the oil seal.
22. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE Removal
23. REMOVE TIMING CHAIN GUIDE Removal
24. REMOVE CHAIN TENSIONER SLIPPER Removal
25. REMOVE NO. 1 CHAIN VIBRATION DAMPER Removal
26. REMOVE CHAIN SUB-ASSEMBLY Removal
27. REMOVE CRANKSHAFT TIMING SPROCKET Removal
28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY Removal
29. REMOVE KEYS

(a) Remove the 2 pulley set keys from the crankshaft.
30. REMOVE NO. 2 CAMSHAFT

(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.
(c) Remove the No. 2 camshaft.
31. REMOVE CAMSHAFT

(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.
(c) Remove the camshaft.

32. REMOVE NO. 1 CAMSHAFT BEARING
Remove the No. 1 camshaft bearing.
33. REMOVE NO. 2 CAMSHAFT BEARING

(a) Remove the No. 2 camshaft bearing.
34. REMOVE CAMSHAFT TIMING SPROCKET

(a) Clamp the camshaft in a vise.
(b) Remove the flange bolt on the camshaft timing sprocket.
35. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY Removal
36. REMOVE CYLINDER HEAD SUB-ASSEMBLY Removal
37. REMOVE CYLINDER HEAD GASKET Removal
38. REMOVE CYLINDER BLOCK WATER JACKET SPACER

(a) Using needle-nose pliers, remove the cylinder block water jacket spacer.
NOTICE: Be sure to remove the water jacket spacer if turning the cylinder block upside down.

39. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (w/o Oil Cooler)

(a) Remove the water drain cock from the stiffening crankcase.
(b) Remove the water drain cock plug from the water drain cocks.
40. REMOVE OIL CONTROL VALVE FILTER

(a) Using an 8 mm socket hexagon wrench, remove the plug and filter.
41. REMOVE NO. 1 TAPER SCREW PLUG (w/o Oil Cooler)

(a) Remove the taper screw plug.
42. REMOVE OIL PUMP ASSEMBLY

(a) Remove the 3 bolts, oil pump and gasket.
43. REMOVE NO. 1 AND NO. 2 BALANCESHAFT SUB-ASSEMBLY

(a) Uniformly loosen and remove the 8 bolts in the sequence shown in the illustration.

(b) Remove the No. 1 and No. 2 balanceshafts.
44. REMOVE NO. 1 BALANCESHAFT BEARING

(a) Remove the balanceshaft bearings.
45. REMOVE ENGINE REAR OIL SEAL

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

46. REMOVE STIFFENING CRANKCASE ASSEMBLY

(a) Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.

(b) Using a screwdriver, 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.

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

(b) Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly.
HINT: The matchmarks on the connecting rods and caps are provided for ensuring the correct reassembly.

(c) Using a 12 mm socket wrench, uniformly loosen the 2 bolts.
(d) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
HINT: Keep the lower bearing inserted in the connecting rod cap.

(e) 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.

48. REMOVE CONNECTING ROD BEARING
(a) Remove the connecting rod bearings.
HINT: Arrange the removed parts in the correct order.

49. REMOVE PISTON RING SET

(a) Using a piston ring expander, remove the 2 compression rings.
(b) Remove the oil ring rail and oil ring expander by hand.
HINT: Arrange the removed parts in the correct order.

50. REMOVE PISTON PIN HOLE SNAP RING

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

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

(b) Using a plastic hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.
HINT:
- The piston and pin are a matched set.
- Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

52. REMOVE CRANKSHAFT

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

(b) Use 2 removed main bearing cap bolts to remove the 5 main bearing caps and 5 lower bearings.
NOTICE:
Insert the bolts into one of the caps. Ease the cap out by gently pulling up and applying force toward the front and back side of the cylinder block, as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block.
HINT:
- Keep the lower bearing and main bearing cap together.
- Arrange the main bearing caps in the correct order.

(c) Lift out the crankshaft.
53. REMOVE UPPER CRANKSHAFT THRUST WASHER

(a) Remove the upper thrust washers from the cylinder block.
54. REMOVE CRANKSHAFT BEARING

(a) Remove the 5 upper main bearings from the cylinder block.
HINT: Arrange the bearings in the correct order.

55. REMOVE NO. 2 CRANKSHAFT BEARING

(a) Remove the 5 lower main bearings from the 5 main bearing caps.
HINT: Arrange the bearings in the correct order.

56. REMOVE STUD BOLT
57. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, remove the bolts and oil nozzles.
58. CLEAN CYLINDER BLOCK
NOTICE: If the cylinder is washed at high temperatures, the cylinder liner will stick out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.