Removal
2ZR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: REMOVAL
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
HINT
Removal.
2. INSTALL ENGINE STAND Removal
3. REMOVE INTAKE MANIFOLD Removal
4. DISCONNECT FUEL TUBE SUB-ASSEMBLY Removal
5. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY Removal
6. REMOVE FUEL INJECTOR ASSEMBLY Removal
7. REMOVE IGNITION COIL ASSEMBLY Removal
8. REMOVE OIL LEVEL DIPSTICK SUB-ASSEMBLY Removal
9. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Removal
10. REMOVE MANIFOLD STAY Removal
11. REMOVE EXHAUST MANIFOLD Removal
12. REMOVE VENTILATION HOSE Removal
13. DISCONNECT NO. 3 WATER BY-PASS HOSE Removal
14. REMOVE NO. 1 WATER BY-PASS PIPE Removal
15. REMOVE WATER BY-PASS HOSE Removal
16. REMOVE INLET WATER HOSE Removal
17. REMOVE INLET WATER Removal
18. REMOVE THERMOSTAT Removal
19. REMOVE RADIO SETTING CONDENSER Removal
20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Disassembly
21. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned.
(b) Check that each timing mark of the camshaft timing gear and sprocket are aligned with each timing mark located as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.
22. REMOVE CRANKSHAFT PULLEY Removal
23. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Disassembly
24. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal
25. REMOVE TIMING CHAIN COVER OIL SEAL Disassembly
26. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the chain tensioner slipper.
27. REMOVE NO. 1 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts and No. 1 chain vibration damper.
28. REMOVE CHAIN SUB-ASSEMBLY
(a) Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to loosen the chain between the camshaft timing gears.
(b) With the chain loosened, release the chain from the camshaft timing gear assembly and place it on the camshaft timing gear assembly.
HINT
Be sure to release the chain from the sprocket completely.
(c) Turn the camshaft clockwise to return it to the original position and remove the chain.
29. REMOVE NO. 2 CHAIN VIBRATION DAMPER Removal
30. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Inspect the lock of the camshaft timing gear.
(b) 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.
NOTICE:
Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.
(c) Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A)
(d) 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.
(e) Forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).
HINT
Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.
(f) Turn the camshaft timing gear assembly within its movable range (26.5 to 28.5°) 2 or 3 times without turning it to the most retarded position. Make sure that the camshaft timing gear assembly turns smoothly.
(g) Remove the adhesive tape from the No. 1 camshaft bearing cap.
31. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
(a) Check the lock of the camshaft timing exhaust gear.
(b) After cleaning and degreasing the VVT oil hole on the exhaust 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.
NOTICE:
Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.
(c) Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure B)
(d) Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the hole pricked in procedure B 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.
(e) Using a screwdriver with its tip wrapped with tape, forcibly turn the camshaft timing exhaust gear in the retard direction (clockwise).
NOTICE:
* Be sure to keep the camshaft timing exhaust gear in the retard direction using a screwdriver. If the gear is released, it will return to the most advanced position automatically due to force from the spring.
* Do not damage the camshaft timing exhaust gear.
(f) Using a screwdriver with its tip wrapped with tape, turn the camshaft timing exhaust gear within its movable range (19 to 21°) 2 or 3 times without turning it to the most advanced position. Make sure that the camshaft timing exhaust gear turns smoothly.
(g) Remove the adhesive tape from the No. 1 camshaft bearing cap.
32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
(a) 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.
33. 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.
34. 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.
NOTICE:
Uniformly loosen the bolts while keeping the camshaft level.
(c) Remove the 5 bearing caps.
HINT
Arrange the removed parts in the correct order.
35. REMOVE CAMSHAFT
(a) Remove the camshaft.
36. REMOVE NO. 2 CAMSHAFT
(a) Remove the No. 2 camshaft.
37. REMOVE NO. 1 CAMSHAFT BEARING Removal
38. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Disassembly
39. REMOVE VALVE LASH ADJUSTER ASSEMBLY Disassembly
40. REMOVE NO. 2 CAMSHAFT BEARING
(a) Remove the 2 No. 2 camshaft bearings.
41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY Disassembly
42. REMOVE CYLINDER HEAD SUB-ASSEMBLY
(a) Using 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.
NOTICE:
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.
NOTICE:
Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
43. REMOVE CYLINDER HEAD GASKET
(a) Remove the cylinder head gasket.
44. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Engine Unit
45. INSPECT VALVE LASH ADJUSTER ASSEMBLY Engine Unit
46. INSPECT CYLINDER HEAD SET BOLT Engine Unit