Disassembly

2AZ-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

(a) Remove the oil filler cap from the cylinder head cover.
2. REMOVE OIL FILLER CAP GASKET

(a) Remove the oil filler cap gasket from the oil filler cap.
3. REMOVE VENTILATION VALVE SUB-ASSEMBLY

(a) Using a 22 mm deep socket wrench, remove the ventilation valve from the cylinder head cover.
4. REMOVE SPARK PLUG Removal
5. REMOVE OIL FILTER SUB-ASSEMBLY Replacement
6. REMOVE OIL FILTER UNION

(a) Using a 12 mm socket hexagon wrench, remove the oil filter union.
7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove the 8 bolts and 2 nuts, remove the cylinder head cover.
8. REMOVE CYLINDER HEAD COVER GASKET

(a) Remove cylinder head cover gasket from the cylinder head cover.
9. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Removal
10. REMOVE CRANKSHAFT POSITION SENSOR

(a) Disengage the wire harness from the harness clamp bracket.
(b) Remove the bolt and crankshaft position sensor.
11. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the bolt and camshaft position sensor.
12. SET NO. 1 CYLINDER TO TDC / COMPRESSION Removal
13. REMOVE CRANKSHAFT PULLEY Removal
14. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Remove the bolt and camshaft timing oil control valve from the cylinder head.
NOTICE: The camshaft timing oil control valve may be damaged when loosening the cylinder head bolt if the camshaft timing oil control valve is not removed.

15. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Removal
16. REMOVE WATER PUMP PULLEY Removal
17. REMOVE WATER PUMP ASSEMBLY Removal
18. REMOVE OIL PAN DRAIN PLUG

(a) Remove the oil pan drain plug from the oil pan.
19. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 12 bolts and 2 nuts.

(b) 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.
NOTICE: Be careful not to damage the contact surface of the crankcase, chain cover and oil pan.

20. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Removal
21. REMOVE FRONT CRANKSHAFT OIL SEAL

(a) Using a screwdriver with its tip wrapped in protective tape, remove the oil seal.
NOTICE: Be careful not to damage the timing chain case oil seal.

22. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE Removal
23. REMOVE TIMING CHAIN GUIDE Removal
24. REMOVE CHAIN TENSIONER SLIPPER Removal
25. REMOVE NO. 1 CHAIN VIBRATION DAMPER Removal
26. REMOVE CHAIN SUB-ASSEMBLY
27. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET Removal
28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY Removal
29. REMOVE NO. 2 CAMSHAFT

(a) Using several steps, uniformly loosen and remove the No. 2 and 4 No. 3 bearing caps in the sequence shown in the illustration.
NOTICE: Uniformly loosen the bolts while keeping the camshaft level.
HINT: Arrange the removed parts in the correct order.

(b) Remove the No. 2 camshaft.
30. REMOVE CAMSHAFT

(a) Using several steps, uniformly loosen and remove the No. 1 and 4 No. 3 bearing caps in the sequence shown in the illustration.
NOTICE: Uniformly loosen the bolts while keeping the camshaft level.
HINT: Arrange the removed parts in the correct order.

(b) Remove the camshaft.
31. REMOVE NO. 1 CAMSHAFT BEARING

(a) Remove the camshaft bearing from the No. 1 camshaft bearing cap.
32. REMOVE NO. 2 CAMSHAFT BEARING

(a) Remove the No. 2 camshaft bearing from the cylinder head.
33. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET

(a) Clamp the camshaft in a vise, and make sure that the camshaft timing gear or sprocket does not rotate.

NOTICE:
- Do not overtighten the vise.
- Do not damage the camshaft.

(b) Remove the bolt and camshaft timing gear or sprocket.
34. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY Removal
35. REMOVE CYLINDER HEAD SUB-ASSEMBLY Removal

36. REMOVE CYLINDER HEAD GASKET
37. REMOVE CYLINDER BLOCK WATER JACKET SPACER

(a) Using needle nose pliers, remove the cylinder block water jacket spacer from the water jacket.
NOTICE: Before turning the cylinder block upside down, make sure that the water jacket spacer is removed, as it will fall out.

38. REMOVE INLET WATER HOUSING DRAIN COCK ASSEMBLY
(a) Remove the plug from the drain cock.
(b) Remove the drain cock from the inlet water housing.
39. REMOVE INLET WATER HOUSING
(a) Using a E5 "TORX" socket wrench, remove the 6 stud bolts from the inlet water housing.

(b) Using several steps, uniformly loosen and remove the 5 bolts and inlet water housing in the sequence shown in the illustration.

(a) Using a socket hexagon wrench 8, remove the plug, gasket and oil control valve filter.
41. REMOVE NO. 1 TAPER HEAD SCREW PLUG

(a) Remove the No. 1 taper head screw plug.
42. REMOVE OIL PUMP ASSEMBLY Removal
43. INSPECT BALANCESHAFT THRUST CLEARANCE Engine Unit
44. INSPECT BALANCESHAFT OIL CLEARANCE Engine Unit
45. REMOVE NO. 1 AND NO. 2 BALANCESHAFTS

(a) Remove the No. 1 and No. 2 balanceshafts.
46. REMOVE NO. 1 BALANCESHAFT BEARING

(a) Remove the 8 No. 1 balanceshaft bearings in the shown in the illustration.
47. REMOVE REAR CRANKSHAFT OIL SEAL Removal
48. REMOVE STIFFENING CRANKCASE ASSEMBLY

(a) Using several steps, uniformly loosen and remove the 11 bolts and in the sequence shown in the illustration.

(b) Remove the crankcase by prying the portions between the crankcase and cylinder block.
NOTICE: Be careful not to damage the contact surfaces of the crankcase and cylinder block.

(c) Remove the O-ring.