Replacement

2ZR-FE ENGINE MECHANICAL: ENGINE UNIT: REPLACEMENT

REPLACEMENT

1. REPLACE RING PIN
(a) Remove the 2 ring pins.





(b) Install 2 new ring pins to the crankcase.
Standard protrusion:
3 mm (0.118 in.)
2. REPLACE STUD BOLT
(a) For crankcase:
(1) Remove the 2 stud bolts.




(2) Using a "TORX" socket E5, install the 2 stud bolts as shown in the illustration.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) For water inlet housing:
(1) Remove the 2 stud bolts.




(2) Using a "TORX" socket E5, install the 2 stud bolts as shown in the illustration.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
3. REPLACE SPARK PLUG TUBE GASKET





(a) Pry up the claws of the ventilation baffle plate.
NOTE: Do not deform the claws of the baffle plate more than necessary.

(b) Remove the 4 gaskets from the cylinder head covers.
NOTICE:
- Prevent the plug tube gaskets from being deformed as much as possible. The removed gaskets will be used when reinstalling the gaskets.
- Do not damage the connection of the cylinder head cover.




(1) Using a cutter, cut off the sealing part of the removed plug tube gasket.




(2) Using the plug tube gasket which has had the sealing part cut off, uniformly press in a new plug tube gasket all the way.

NOTICE:
- Keep the lip free of foreign matter.
- Do not tap on the oil seal at an angle.
HINT: If a plug tube gasket that will be used to install a new gasket is deformed, and cannot be positioned on a new gasket, correct the deformation using pliers.

(c) Return the claws of the ventilation baffle plate to their original positions.
4. REPLACE 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 oil seal.
HINT: Tape the screwdriver tip before use.





(b) Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
SST: 09223-22010
(c) Apply a light coat of MP grease to the lip of the oil seal.
NOTICE:
- Keep the lip free of foreign matter.
- Do not tap on the oil seal at an angle.
- Make sure that the oil seal edge does not stick out of the timing chain cover.

5. REPLACE 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.





(c) Using SST and a hammer, evenly tap the oil seal until its surface is flush with the rear oil seal retainer edge.
SST: 09223-15030
SST: 09950-70010
09951-07100

NOTICE:
- Keep the lip free of foreign matter.
- Do not tap on the oil seal at an angle.

(d) Apply MP grease to a new oil seal lip.
NOTE: Wipe off extra grease on the crankshaft.