Part 1

2ZR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

DISASSEMBLY

1. REMOVE ENGINE HANGER

(a) Remove the 2 bolts and 2 engine hangers.
2. REMOVE OIL FILLER CAP SUB-ASSEMBLY

(a) Remove the oil filler cap.
3. REMOVE OIL FILLER CAP GASKET

(a) Remove the oil filler cap gasket.
4. REMOVE SPARK PLUG

(a) Using a 14 mm socket wrench, remove the 4 spark plugs.
5. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the 2 bolts and 2 sensors.
6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Remove the 2 bolts, 2 O-rings, bracket and 2 oil control valves.
7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove the 13 bolts, seal washer and cylinder head cover.

(b) Remove the 3 gaskets from the camshaft bearing cap.
NOTE: When removing the cylinder head cover, some of the gaskets may stick to it so be careful not to drop any of the gaskets into the engine.

8. REMOVE CYLINDER HEAD COVER GASKET

(a) Remove the cylinder head cover gasket.
9. SET NO. 1 CYLINDER TO TDC / COMPRESSION

(a) Turn the crankshaft pulley, and align its timing notch with the "0" timing mark on the timing chain cover sub-assembly.
(b) Check that timing marks on both the camshaft timing exhaust gear and camshaft timing gear are facing upward, as shown in the illustration.
HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

10. REMOVE CRANKSHAFT PULLEY

(a) Using SST, hold the pulley in place and loosen the pulley bolt.
SST: 09213-58013
91651-60855
SST: 09330-00021

(b) Using SST, remove the pulley bolt and pulley.
SST: 09950-50013
09951-05010
09952-05010
09953-05020
09954-05021
11. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Remove the 2 nuts, bracket, No. 1 chain tensioner assembly and gasket.
NOTE: Do not turn the crankshaft after you have removed the chain tensioner.

12. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the bolt and crankshaft position sensor.
13. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
14. REMOVE NO. 1 TAPER SCREW PLUG

(a) Remove the No. 1 taper screw plug.
15. REMOVE KNOCK SENSOR

(a) Remove the bolt and knock sensor.
16. REMOVE ENGINE WATER TEMPERATURE SENSOR

(a) Using a 19 mm deep socket wrench, remove the engine water temperature sensor.
(b) Remove the gasket from the engine water temperature sensor.
17. REMOVE OIL FILTER SUB-ASSEMBLY

(a) Using SST, remove the oil filter cap.
SST: 09228-06501
HINT: Use a container to catch the draining oil. After the oil filter cap is loosened approximately 4 turns and the cap rib is facing straight down, engine oil will begin to drain from the gap between the oil filter cap and oil pan.

(b) Remove the oil filter element and O-ring from the oil filter cap.
NOTE: Be sure to remove the O-ring (for the cap) by hand, without using any tools, to prevent damage to the O-ring groove on the cap.

18. REMOVE WATER INLET

(a) Remove the 2 nuts and remove the water inlet.
19. REMOVE THERMOSTAT

(a) Remove the thermostat from the cylinder block.
(b) Remove the gasket from the thermostat.
20. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

(a) Remove the 3 bolts and remove the engine mounting bracket RH.

(b) Remove the 4 bolts and remove the oil filter bracket.

(d) Remove the 19 bolts.

(e) Remove the timing chain or belt cover sub-assembly by prying between the timing chain or belt cover sub-assembly and cylinder head or cylinder block with a screwdriver wrapped in protective tape.
NOTE: Be careful not to damage the contact surfaces of the timing chain or belt cover sub-assembly, cylinder block and cylinder head.

(f) Remove the 3 O-rings from the cylinder head and cylinder block.

(g) Remove the 3 bolts and the water pump assembly.

(h) Remove the gasket from the timing chain or belt cover sub-assembly.
21. REMOVE WATER INLET HOUSING

(a) Remove the 3 bolts, gasket and water inlet housing.
22. REMOVE NO. 1 GENERATOR BRACKET

(a) Remove the 4 bolts and generator bracket.
23. REMOVE NO. 2 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and remove the No. 2 chain vibration damper.
24. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the chain tensioner slipper from the cylinder block.