Part 1

1NZ-FXE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

DISASSEMBLY

1. REMOVE SPARK PLUG
(a) Using a 16 mm plug wrench, remove the 4 spark plugs.
2. REMOVE OIL FILLER CAP
(a) Remove the oil filler cap from the cylinder head cover.
3. REMOVE OIL FILLER CAP GASKET

(a) Using a screwdriver, remove the gasket from the oil filler cap.
HINT: Tape the screwdriver tip before use.

4. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the bolt and sensor.
5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Remove the bolt and oil control valve.
6. REMOVE OIL FILTER

(a) Using SST, remove the oil filter.
SST: 09228-06501
7. REMOVE THERMOSTAT

(a) Remove the 2 nuts and water inlet.

(b) Remove the thermostat.
(c) Remove the gasket from the thermostat.
8. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the bolt and sensor.
9. REMOVE WATER PUMP PULLEY

(a) Using SST, hold the pump pulley and remove the 3 bolts and pump pulley.
SST: 09960-10010
09962-01000
09963-00600
10. REMOVE WATER PUMP

(a) Remove the 3 bolts and 2 nuts.
(b) Remove the water pump and gasket.
11. REMOVE ENGINE MOUNTING BRACKET RH

(a) Remove the 4 bolts and engine mounting bracket RH.
12. REMOVE VENTILATION VALVE

(a) Remove the ventilation valve from the cylinder head cover.
13. REMOVE CYLINDER HEAD COVER

(a) Remove the 9 bolts, 2 nuts and cylinder head cover.
(b) Remove the gasket from the cylinder head cover.
14. REMOVE CRANKSHAFT PULLEY

(a) Set the No. 1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley until its timing notch and timing mark 0 of the chain cover are aligned.
(2) Check that both timing marks on the camshaft timing sprocket and the camshaft timing gear are facing upward as shown in the illustration.
If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

(b) Using SST, hold the crankshaft pulley and loosen the crankshaft pulley set bolt.
SST: 09213-58012
91111-50845
SST: 09330-00021
NOTE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover.

(c) Loosen the crankshaft pulley set bolts until 2 to 3 threads of the bolt is tightened to the crankshaft.
(d) Using SST, remove the crankshaft pulley and crankshaft pulley set bolt.
SST: 09950-50013
09951-05010
09952-05010
09953-05020
09954-05021

(e) Remove the crankshaft straight pin.
15. REMOVE TIMING CHAIN COVER

(a) Remove the 15 bolts and nut.

(b) Using a screwdriver with the tip wrapped in tape, remove the chain cover by prying between the cylinder head and cylinder block.
NOTE: Be careful not to damage the contact surfaces of the chain cover, the cylinder head and the cylinder block.

(d) Using an 8 mm hexagon wrench, remove the screw plug from the oil pump.
16. REMOVE OIL PUMP SEAL Replacement
17. REMOVE NO. 1 CHAIN TENSIONER
NOTICE:
- When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from TDC and align the oil jet hole with the paint mark to prevent the pistons from coming into contact with the valves.

- Do not rotate the crankshaft with the chain tensioner removed.

(a) Lift up the stopper plate, then unlock the plunger.
(b) Push in the plunger to the end with the plunger unlocked.

(c) Lower the stopper plate with the plunger pushed to the end, then lock the plunger.
(d) Insert a 3.0 mm (0.118 in.) diameter bar into the hole of the stopper plate with the plunger locked.

HINT: If the stopper plate is not completely lowered and a 3.0 mm (0.118 in.) diameter bar cannot be inserted, unlock and pull out the plunger slightly. Then the stopper plate will be completely lowered and a 3.0 mm (0.118 in.) diameter bar can be inserted easily.

(e) Remove the 2 bolts and chain tensioner.
18. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the bolt and chain tensioner slipper.
19. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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

(a) Remove the chain from the engine.
21. REMOVE FUEL DELIVERY PIPE

(a) Remove the 3 bolts and fuel delivery pipe together with the 4 fuel injectors.

(b) Remove the delivery pipe spacer from the cylinder head.
22. REMOVE FUEL INJECTOR

(a) Pull out the 4 injectors from the delivery pipe.
23. REMOVE NO. 2 CAMSHAFT

(a) Using several steps, uniformly loosen and remove the 11 bearing cap bolts in the sequence shown in the illustration, and then remove the 5 bearing caps and No. 2 camshaft.
NOTE: Loosen each bolt uniformly, keeping the camshaft level.

24. REMOVE CAMSHAFT TIMING SPROCKET

(a) Clamp the camshaft in a vise.
(b) Remove the flange bolt and camshaft timing sprocket.
NOTE: Be careful not to damage the camshaft.

25. REMOVE CAMSHAFT

(a) Using several steps, uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration, and then remove the 4 bearing caps and camshaft.
NOTE: Loosen each bolt uniformly, keeping the camshaft level.

26. REMOVE CAMSHAFT TIMING GEAR

(a) Turn the valve timing controller assembly at the most advanced angle Testing and Inspection.
(b) Remove the flange bolt and camshaft timing gear.
NOTICE:
- Be careful not to remove the other 4 bolts.
- If reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first.

27. REMOVE CYLINDER HEAD

(a) Using several steps, uniformly loosen and remove the 10 cylinder head bolts with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

NOTICE:
- Be careful not to drop washers into the cylinder head.
- Head warpage or cracking could result from removing bolts in the incorrect order.

28. REMOVE CYLINDER HEAD GASKET
29. REMOVE OIL FILTER UNION

(a) Using a 12 mm hexagon wrench, remove the oil filter union.
30. REMOVE NO. 2 OIL PAN

(a) Remove the oil pan drain plug and gasket.
(b) Remove the 9 bolts and 2 nuts.

(c) Insert the blade of oil pan seal cutter between the oil pan and No. 2 oil pan, cut off the applied sealer and remove the No. 2 oil pan.
NOTE: Be careful not to damage the oil pan and No. 2 oil pan.

31. REMOVE OIL STRAINER

(a) Remove the bolt, 2 nuts, oil strainer and gasket.
32. REMOVE OIL PAN

(a) Loosen and remove the 13 bolts uniformly in several steps.

(b) Using a screwdriver, remove the oil pan by prying between the cylinder block and oil pan.
NOTE: Be careful not to damage the contact surfaces of the oil pan and cylinder block.
HINT: Tape the screwdriver tip before use.

(d) Using an E5 "TORX" socket, remove the 4 stud bolts.

33. REMOVE ENGINE REAR OIL SEAL