Diesel Data: Automotive Repair
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Removal








1NZ-FE ENGINE MECHANICAL: CYLINDER HEAD: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
Technician Safety Information
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE FRONT WIPER ARM HEAD CAP (for Hatchback) Removal
4. REMOVE FRONT WIPER ARM HEAD CAP (for Sedan) Removal
5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Hatchback) Removal
6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (for Sedan) Removal
7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Hatchback) Removal
8. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (for Sedan) Removal
9. REMOVE HOOD TO COWL TOP SEAL (for Hatchback) Removal
10. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Hatchback) Removal
11. REMOVE COWL TOP VENTILATOR LOUVER LH (for Hatchback) Removal
12. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan) Removal
13. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan) Removal
14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Sedan) Removal
15. REMOVE FRONT WIPER MOTOR AND LINK (for Hatchback) Removal
16. REMOVE FRONT WIPER MOTOR AND LINK (for Sedan) Removal
17. REMOVE COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2 (for Hatchback) Removal
18. REMOVE FRONT AIR SHUTTER SEAL RH (for Sedan) Removal
19. REMOVE COWL TOP PANEL OUTER (for Hatchback) Removal
20. REMOVE COWL TOP PANEL OUTER (for Sedan) Removal
21. REMOVE BATTERY
22. REMOVE BATTERY TRAY
23. REMOVE FRONT WHEEL RH
24. REMOVE ENGINE UNDER COVER RH
25. DRAIN ENGINE OIL
26. DRAIN ENGINE COOLANT Service and Repair
27. REMOVE CYLINDER HEAD COVER NO. 2 Removal
28. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE NO. 1 Removal





29. DISCONNECT RADIATOR HOSE NO. 3
(a) Disconnect radiator hose No. 3.





30. DISCONNECT RESERVE TANK HOSE
(a) Disconnect the reserve tank hose.





31. REMOVE WATER FILLER SUB-ASSEMBLY
(a) Separate radiator hose No. 1 from the cylinder head.
(b) Remove the 2 nuts and remove the water filler sub-assembly.





32. DISCONNECT WATER BY-PASS HOSE NO. 2
(a) Disconnect water by-pass hose No. 2.





33. DISCONNECT WATER BY-PASS HOSE
(a) Disconnect the water by-pass hose.





34. DISCONNECT THROTTLE WITH MOTOR BODY CONNECTOR
(a) Separate the wire harness clamp.
(b) Remove the nut and separate the throttle with motor body connector.





35. DISCONNECT VENTILATION HOSE
(a) Disconnect the ventilation hose.





36. DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a) Disconnect the union to connector tube hose.
37. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY
38. REMOVE INTAKE MANIFOLD





(a) Separate the 3 wire harness clamps shown in the illustration.





(b) Remove the 3 bolts and 2 nuts and remove the intake manifold.





39. REMOVE OIL LEVEL GAUGE GUIDE
(a) Remove the wire harness clamp and the bolt and remove the oil level gauge guide.
40. DISCONNECT FUEL TUBE SUB-ASSEMBLY Removal





41. DISCONNECT BOOSTER VACUUM TUBE
(a) Disconnect the booster vacuum tube.





42. DISCONNECT CAMSHAFT POSITION SENSOR CONNECTOR
(a) Disconnect the camshaft position sensor connector.





43. DISCONNECT ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR
(a) Disconnect the engine coolant temperature sensor connector.





44. DISCONNECT HEATED OXYGEN SENSOR CONNECTOR
(a) Remove the bolts and separate the sensor bracket.
(b) Disconnect the heated oxygen sensor connector.





45. DISCONNECT HEATER WATER INLET HOSE A
(a) Disconnect heater water inlet hose A.





46. SEPARATE WATER BY-PASS PIPE NO. 1
(a) Remove the bolt and separate water by-pass pipe No. 1.





47. DISCONNECT WIRE HARNESS
(a) Remove the 2 bolts and disconnect the wire harness.





48. SEPARATE EXHAUST PIPE ASSEMBLY FRONT
(a) Remove the 2 bolts and 2 compression springs and separate the exhaust pipe assembly front.





49. REMOVE MANIFOLD SUPPORT BRACKET
(a) Remove the 3 bolts and remove the manifold support bracket.
50. REMOVE FAN AND GENERATOR V BELT Removal
51. REMOVE GENERATOR ASSEMBLY Removal
52. REMOVE IGNITION COIL NO. 1 Removal
53. REMOVE VENTILATION HOSE Removal
54. REMOVE VENTILATION HOSE NO. 2 Removal
55. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Removal
56. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH Removal
57. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY Removal
58. REMOVE CRANKSHAFT POSITION SENSOR Removal
59. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Removal
60. REMOVE WATER PUMP PULLEY Removal
61. REMOVE WATER PUMP ASSEMBLY Removal
62. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Removal
63. REMOVE OIL PUMP ASSEMBLY Removal
64. REMOVE OIL PUMP SEAL Replacement
65. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1 Removal
66. REMOVE CHAIN TENSIONER SLIPPER Removal
67. REMOVE CHAIN VIBRATION DAMPER NO. 1 Removal
68. REMOVE CHAIN SUB-ASSEMBLY
69. REMOVE CAMSHAFT
NOTE: When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.





(a) Using several steps, uniformly loosen and remove the 19 bearing cap bolts in the sequence shown in the illustration, and then remove camshaft bearing cap No. 1 and camshaft bearing cap No. 2.
NOTE: Loosen each bolt uniformly while keeping the camshaft level.

(b) Remove the camshaft and camshaft No. 2.





70. REMOVE CYLINDER HEAD SUB-ASSEMBLY
(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 plate washers.
NOTICE:
- Do not drop the washers into the cylinder head.
- Head warpage or cracking could result from removing the bolts in the wrong order.





71. REMOVE CYLINDER HEAD GASKET
(a) Remove the cylinder head gasket.





72. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1
(a) Remove the 4 bolts and remove exhaust manifold heat insulator No. 1.





73. REMOVE EXHAUST MANIFOLD
(a) Remove the 3 bolts and 2 nuts and remove the exhaust manifold.





74. REMOVE HARNESS BRACKET
(a) Remove the bolt and remove the harness bracket.





75. REMOVE BOOSTER VACUUM TUBE
(a) Remove the 2 bolts and remove the booster vacuum tube.





76. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and remove the camshaft position sensor.





77. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a) Using SST, remove the engine coolant temperature sensor connector.
SST: 09817-33190





78. REMOVE WATER BY-PASS HOSE
(a) Remove the water by-pass hose.





79. REMOVE HARNESS BRACKET
(a) Remove the bolt and remove the harness bracket.





80. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
(a) Remove the 3 bolts and remove the fuel delivery pipe sub-assembly with 4 fuel injectors.
NOTE: Do not drop the fuel injectors when removing the fuel delivery pipe sub-assembly.

81. REMOVE FUEL INJECTOR ASSEMBLY Removal





82. REMOVE DELIVERY PIPE NO. 1 SPACER
(a) Remove the 2 delivery pipe No. 1 spacers.





83. REMOVE INJECTOR VIBRATION INSULATOR
(a) Remove the 4 injector vibration insulators.
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