Disassembly

2ZR-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 gasket from the oil filler cap.
3. REMOVE ENGINE COVER JOINT





(a) Remove the 2 engine cover joints.
4. REMOVE SPARK PLUG





(a) Using a 14 mm spark plug 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, 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.
NOTE: Be careful not to drop any of the gaskets into the engine when removing the cylinder head cover because the gaskets may stick to the cylinder head cover.





(b) Remove the cylinder head cover gasket.





(c) Remove the 3 gaskets from the camshaft bearing cap.
8. SET NO. 1 CYLINDER TO TDC/COMPRESSION Removal
9. REMOVE CRANKSHAFT PULLEY Removal
10. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY





(a) Remove the 2 nuts, bracket, tensioner and gasket.
NOTE: Do not turn the crankshaft without the chain tensioner installed.

11. REMOVE CRANKSHAFT POSITION SENSOR





(a) Remove the bolt and sensor.
12. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY





(a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
13. REMOVE NO. 1 TAPER SCREW PLUG





(a) Remove the taper screw plug.
14. REMOVE KNOCK CONTROL SENSOR





(a) Remove the bolt and sensor.
15. REMOVE ENGINE COOLANT TEMPERATURE SENSOR





(a) Using a 19 mm deep socket wrench, remove the sensor.
(b) Remove the gasket from the engine coolant temperature sensor.
16. REMOVE OIL FILTER CAP ASSEMBLY Replacement
17. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal
18. REMOVE TIMING CHAIN COVER OIL SEAL





(a) Using a screwdriver and hammer, remove the oil seal.
NOTE: Be careful not to damage the timing chain cover.
HINT: Tape the screwdriver tip before use.

19. REMOVE INLET WATER HOUSING





(a) Remove the 3 bolts, gasket and inlet water housing.
20. REMOVE NO. 1 GENERATOR BRACKET





(a) Remove the 4 bolts and No. 1 generator bracket.
21. REMOVE CHAIN TENSIONER SLIPPER Removal
22. REMOVE NO. 1 CHAIN VIBRATION DAMPER Removal
23. REMOVE CHAIN SUB-ASSEMBLY Removal
24. REMOVE NO. 2 CHAIN VIBRATION DAMPER Removal
25. REMOVE CRANKSHAFT TIMING SPROCKET Removal
26. REMOVE NO. 2 CHAIN SUB-ASSEMBLY Removal
27. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE





(a) Remove the No. 1 crankshaft position sensor plate.
28. REMOVE CRANKSHAFT TIMING GEAR KEY





(a) Using a screwdriver, remove the 2 crankshaft timing gear keys.
HINT: Tape the screwdriver tip before use.

29. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
(a) Check the lock of the camshaft timing gear.
(b) Release the lock pin.
NOTE: 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.
NOTE: 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 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.
- 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, 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.

30. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY





(a) Remove the flange bolt while holding the hexagonal portion of the camshaft, 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.

31. 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.
NOTE: Uniformly loosen the bolts while keeping the camshaft level.

(c) Remove the 5 bearing caps.
HINT: Arrange the removed parts in the correct order.

32. REMOVE CAMSHAFT





(a) Remove the camshaft.
33. REMOVE NO. 2 CAMSHAFT





(a) Remove the No. 2 camshaft.
34. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY





(a) Remove the 16 valve rocker arms.
HINT: Arrange the removed parts in the correct order.

35. 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.

36. REMOVE OIL CONTROL VALVE FILTER





(a) Remove the oil control valve filter.
37. REMOVE NO. 1 CAMSHAFT BEARING





(a) Remove the 2 No. 1 camshaft bearings.
38. REMOVE NO. 2 CAMSHAFT BEARING





(a) Remove the 2 No. 2 camshaft bearings.
39. 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.
NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.
HINT: Tape the screwdriver tip before use.

40. REMOVE CYLINDER HEAD SUB-ASSEMBLY Removal
41. REMOVE CYLINDER HEAD GASKET Removal
42. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY





(a) Remove the water drain cock plug from the water drain cock sub-assembly.
(b) Remove the cylinder block water drain cock sub-assembly from the cylinder block.
43. REMOVE VENTILATION VALVE SUB-ASSEMBLY





(a) Remove the ventilation valve.
44. REMOVE OIL PAN DRAIN PLUG





(a) Remove the oil pan drain plug and gasket.
45. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY Removal
46. REMOVE OIL PUMP ASSEMBLY Removal
47. REMOVE REAR ENGINE 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.
NOTE: After removing the oil seal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper.

48. REMOVE STIFFENING CRANKCASE ASSEMBLY





(a) Uniformly loosen and remove the 11 bolts.





(b) Using a screwdriver, remove the crankcase by prying between the crankcase and cylinder block.
NOTE: Be careful not to damage the contact surfaces of the crankcase and cylinder block.