Removal

2AZ-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE Removal
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE FRONT WIPER ARM HEAD CAP Removal
4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal
5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal
6. REMOVE HOOD TO COWL TOP SEAL Removal
7. REMOVE CENTER NO. 1 COWL TOP VENTILATOR LOUVER Removal
8. REMOVE COWL TOP VENTILATOR LOUVER LH Removal
9. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Removal
10. REMOVE OUTER COWL TOP PANEL Removal
11. REMOVE SUSPENSION TOWER DAMPER ASSEMBLY (w/ Front Strut Bar) Removal
12. REMOVE FRONT WHEEL RH
13. REMOVE ENGINE UNDER COVER LH
14. REMOVE ENGINE UNDER COVER RH
15. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY Removal
16. DRAIN ENGINE COOLANT Service and Repair
17. DRAIN ENGINE OIL Replacement
18. REMOVE CENTER EXHAUST PIPE ASSEMBLY Removal
19. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal
20. REMOVE V-RIBBED BELT Removal
21. REMOVE GENERATOR ASSEMBLY Removal
22. SEPARATE RADIATOR RESERVE TANK ASSEMBLY Removal
23. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE Removal
24. REMOVE THROTTLE BODY ASSEMBLY Removal
25. REMOVE IGNITION COIL ASSEMBLY Removal
26. REMOVE SPARK PLUG Removal
27. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Removal
28. REMOVE ENGINE OIL LEVEL DIPSTICK
29. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Remove the bolt and engine oil level dipstick guide.
(b) Remove the O-ring from the engine oil level dipstick guide.
30. DISCONNECT FUEL MAIN TUBE Removal
31. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY Removal
32. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Removal
33. REMOVE INTAKE MANIFOLD Removal
34. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR Removal
35. REMOVE MANIFOLD STAY Removal
36. REMOVE NO. 2 MANIFOLD STAY Removal
37. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Removal
38. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

(a) Disconnect the air-fuel ratio sensor connector.

(b) Remove the 5 nuts, exhaust manifold converter sub-assembly and gasket.
39. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

(a) Place a wooden block between a floor jack and the engine, then support the engine using the floor jack.

(b) Remove the 4 bolts and 2 nuts, then remove the engine mounting insulator sub-assembly RH.
NOTE: Do not apply excessive force to the return tube when removing the engine mounting insulator sub-assembly RH.
HINT: Keep clearance by lowering the engine using the floor jack when removing the front engine mounting insulator.

40. REMOVE IDLER PULLEY SUB-ASSEMBLY

(a) Loosen the 2 bolts and remove the idler pulley sub-assembly with the 2 bolts.
41. REMOVE OIL PAN SUB-ASSEMBLY

(a) Install the No. 1 and No. 2 engine hangers with new bolts.
Torque: 38 Nm (387 kgf-cm, 28 ft-lbf)

(b) Attach the sling device to the engine hangers and chain block.

(d) Insert the blade of oil pan seal cutter between the crankcase, chain cover and oil pan, then cut through the applied sealer and remove the oil pan.
NOTE: Be careful not to damage the contact surface of the crankcase, chain cover or oil pan.

42. SET NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Turn the crankshaft pulley until the groove and the timing mark "0" on the timing chain cover are aligned.
(b) Check that each timing mark on the camshaft timing gear and sprocket is aligned with the timing marks located on the No. 1 and No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) to align the timing marks as above.
43. REMOVE CRANKSHAFT PULLEY Removal
44. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Remove the 2 nuts, No. 1 chain tensioner assembly and gasket.
NOTE: Do not turn the crankshaft without the No. 1 chain tensioner assembly.

45. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Lift the engine upward.
NOTE: Do not lift the engine more than necessary.

(b) Remove the bolt, nut and V-ribbed belt tensioner assembly.
46. REMOVE CRANKSHAFT POSITION SENSOR Removal
47. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Removal
48. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

(a) Remove the No. 1 crankshaft position sensor plate.
49. REMOVE TIMING CHAIN GUIDE

(a) Remove the bolt and timing chain guide.
50. REMOVE CHAIN TENSIONER SLIPPER

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

(a) Remove the 2 bolts and No. 1 chain vibration damper.
52. REMOVE CHAIN SUB-ASSEMBLY
53. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

(a) Remove the crankshaft timing gear or sprocket from the crankshaft.
54. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft 90° counterclockwise to align the adjusting hole on the oil pump drive shaft sprocket with the groove on the oil pump.

(b) Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft sprocket to lock the gear in position, and then remove the nut.

(c) Remove the bolt, chain tensioner plate and spring.
(d) Remove the oil pump drive sprocket, oil pump drive shaft sprocket and No. 2 chain.
55. DISCONNECT NO. 1 RADIATOR HOSE Removal
56. DISCONNECT OUTLET HEATER WATER HOSE Removal
57. DISCONNECT INLET HEATER WATER HOSE Removal
58. DISCONNECT ENGINE WIRE

(a) Disconnect the radio setting condenser connector.
(b) Disconnect the engine oil pressure switch connector.
(c) Disconnect the engine coolant temperature sensor connector.
(d) Disconnect the camshaft position sensor connector.
(e) Remove the bolt and ground cable.
59. REMOVE NO. 2 CAMSHAFT Disassembly
60. REMOVE CAMSHAFT Disassembly
61. REMOVE NO. 1 CAMSHAFT BEARING Disassembly
62. REMOVE NO. 2 CAMSHAFT BEARING Disassembly
63. REMOVE CYLINDER HEAD SUB-ASSEMBLY

(a) In several steps, uniformly loosen and remove the 10 cylinder head bolts and 10 plate washers with a 10 mm bi-hexagon wrench in the sequence shown in the illustration.
NOTE: Head warpage or cracking could result from removing the bolts in the wrong order.

(b) Using a screwdriver with its tip wrapped with tape, pry between the cylinder head and cylinder block, and remove the cylinder head.
NOTE: Be careful not to damage the contact surfaces between the cylinder head and cylinder block.

64. REMOVE CYLINDER HEAD GASKET