Part 1

PARTIAL ENGINE ASSEMBLY (2AZ-FE)
OVERHAUL
1. REMOVE SPARK PLUG
2. REMOVE OIL FILLER CAP SUB-ASSEMBLY
3. REMOVE OIL FILLER CAP GASKET
4. REMOVE VENTILATION VALVE SUB-ASSEMBLY





5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove the 8 bolts and 2 nuts, then remove the cylinder head cover.
6. REMOVE CYLINDER HEAD COVER GASKET





7. REMOVE OIL FILTER SUB-ASSEMBLY
a. Using SST, remove the oil filter.
SST 09228-06501
8. REMOVE OIL FILTER UNION
a. Using a socket hexagon wrench 12, remove the oil filter union.
9. REMOVE CAMSHAFT POSITION SENSOR
10. REMOVE CRANKSHAFT POSITION SENSOR





11. REMOVE WATER PUMP PULLEY
a. Using SST, remove the 4 bolts and water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)





12. REMOVE WATER PUMP ASSEMBLY
a. Remove the 4 bolts, 2 nuts, bracket and water pump.
13. REMOVE OIL PAN DRAIN PLUG
a. Remove the oil pan drain plug and gasket.





14. REMOVE OIL PAN SUB-ASSEMBLY
a. Remove the 12 bolts and 2 nuts.





b. Insert the blade of SST between the crankcase, chain cover and oil pan, then cut off the applied sealer and remove the oil pan.
SST 09032-00100

NOTICE: Be careful not to damage the contact surface of the crank case, chain cover and oil pan.





15. REMOVE CRANKSHAFT PULLEY
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 gears is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration. If not, turn the crankshaft by 1 revolution (360°) and align the timing marks as above.





c. Using SST, fix the pulley and loosen the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021





d. Using SST and pulley bolt, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)





16. REMOVE CHAIN TENSIONER ASSEMBLY NO.1
a. Remove the 2 nuts, chain tensioner and gasket.

NOTICE: Do not turn the crankshaft without the chain tensioner.





17. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove the 14 bolts and 2 nuts.
b. Remove the timing chain cover by prying the portions between the timing chain cover, cylinder head and cylinder block with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.





18. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
a. Using a screwdriver and hammer, tap out the oil seal.
19. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1





20. REMOVE TIMING CHAIN GUIDE
a. Remove the bolt and timing chain guide.
21. REMOVE CHAIN TENSIONER SLIPPER
a. Remove the bolt and chain tensioner slipper.
22. REMOVE CHAIN SUB-ASSEMBLY
23. REMOVE CHAIN VIBRATION DAMPER NO.1
a. Remove the 2 bolts and chain vibration damper.
24. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET





25. REMOVE NO.2 CHAIN SUB-ASSEMBLY
a. Turn the crankshaft counterclockwise by 90° to align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.





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





c. Remove the bolt, then remove the chain tensioner plate and spring.
d. Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain.





26. REMOVE OIL PUMP ASSEMBLY
a. Remove the 3 bolts, then remove the oil pump and gasket.





27. REMOVE CAMSHAFTS
a. Using several steps, uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration.
b. Remove the 10 bearing caps, then remove the camshaft and No. 2 camshaft.
28. REMOVE CAMSHAFT BEARING NO.1
a. Remove the camshaft bearing No. 1 from the camshaft bearing cap No. 1.





29. REMOVE CAMSHAFT BEARING NO.2
a. Remove the camshaft bearing No. 2 from the cylinder head.





30. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET
a. Clamp the camshaft in a vise, then remove the bolt and camshaft timing gear.

NOTICE: Be careful not to damage the camshaft.





31. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
a. Clamp the camshaft in a vise, and make sure that the camshaft timing gear does not rotate.
b. Cover all the oil ports with vinyl tape except the advance side port shown in the illustration.





c. Apply air pressure to the oil port of 100 kPa (1.0 kgf/cm2 14 psi), then turn the camshaft timing gear to the advance direction (counterclockwise) by hand.

CAUTION: Cover the paths with a shop rag to avoid oil splashes.

HINT: Depending on the air pressure, the camshaft timing gear will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released.





d. Remove the fringe bolt of the camshaft timing gear.

NOTICE:
- Be sure not to remove the other 4 bolts.
- When reusing the camshaft timing gear, release the straight pin lock first, then install the gear.

32. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Remove the bolt, then remove the camshaft timing oil control valve.
b. Remove the O-ring from the camshaft timing oil control valve.





33. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a. Using several steps, uniformly loosen and remove the 10 cylinder head bolts with a bi-hexagon wrench 10 mm in the sequence shown in the illustration. Remove the 10 cylinder head bolts and 10 plate washers.

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