Removal

2ZR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE

Precaution

2. REMOVE BATTERY Removal

3. REMOVE BATTERY TRAY

4. REMOVE FRONT WHEELS

5. REMOVE ENGINE UNDER COVER LH

6. REMOVE ENGINE UNDER COVER RH

7. DRAIN ENGINE COOLANT Service and Repair

8. DRAIN ENGINE OIL Replacement

9. REMOVE FRONT WIPER ARM HEAD CAP Removal

10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal

11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal

12. REMOVE HOOD TO COWL TOP SEAL Removal

13. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal

14. REMOVE COWL TOP VENTILATOR LOUVER LH Removal

15. REMOVE FRONT WIPER MOTOR AND LINK Removal

16. REMOVE FRONT AIR SHUTTER SEAL RH Removal

17. REMOVE OUTER COWL TOP PANEL Removal

18. REMOVE AIR CLEANER ASSEMBLY Removal

19. REMOVE AIR CLEANER BRACKET Removal

20. REMOVE BATTERY CARRIER Removal

21. REMOVE NO. 2 CYLINDER HEAD COVER Removal

22. REMOVE FAN AND GENERATOR V BELT Removal

23. REMOVE NO. 2 RADIATOR HOSE Removal

24. DISCONNECT NO. 1 RADIATOR HOSE Removal

25. REMOVE FRONT BUMPER COVER Removal

26. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transaxle) Removal

27. DISCONNECT NO. 2 OIL COOLER INLET HOSE (for Automatic Transaxle) Removal

28. REMOVE HOOD LOCK ASSEMBLY Removal

29. REMOVE NO. 1 COOLER COVER Removal

30. REMOVE UPPER RADIATOR SUPPORT ABSORBER Disassembly

31. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY Removal

32. REMOVE RADIATOR ASSEMBLY Removal

33. SEPARATE WITH PULLEY COMPRESSOR ASSEMBLY Removal

34. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) Removal

35. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) Removal

36. SEPARATE UNION TO CHECK VALVE HOSE Removal

37. SEPARATE NO. 1 FUEL VAPOR FEED HOSE Removal

38. DISCONNECT ENGINE WIRE Removal

39. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) Removal

40. DISCONNECT HEATER WATER HOSE INLET A Removal

41. DISCONNECT FUEL TUBE SUB-ASSEMBLY (for Manual Transaxle) Removal

42. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) Removal

43. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal

44. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY Removal

45. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Removal

46. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) Removal

47. REMOVE CONSOLE PANEL UPPER Removal

48. REMOVE CONSOLE BOX COVER REAR Removal

49. REMOVE CONSOLE BOX CARPET Removal

50. REMOVE REAR CONSOLE BOX ASSEMBLY Removal

51. REMOVE FRONT CONSOLE BOX Removal

52. REMOVE FRONT FLOOR BRACE CENTER Removal

53. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

54. REMOVE FRONT AXLE SHAFT LH NUT Removal

55. REMOVE FRONT AXLE SHAFT RH NUT

HINT
The removal procedure for the RH side is the same as that for the LH side.

56. SEPARATE SPEED SENSOR FRONT LH Removal

57. SEPARATE SPEED SENSOR FRONT RH

HINT
The separation procedure for the RH side is the same as that for the LH side.

58. SEPARATE TIE ROD END SUB-ASSEMBLY LH Removal

59. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT
The separation procedure for the RH side is the same as that for the LH side.

60. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal

61. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT
The separation procedure for the RH side is the same as that for the LH side.

62. SEPARATE FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY LH Removal

63. SEPARATE FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY RH

HINT
The separation procedure for the RH side is the same as that for the LH side.

64. SEPARATE FRONT AXLE ASSEMBLY LH Removal

65. SEPARATE FRONT AXLE ASSEMBLY RH

HINT
The separation procedure for the RH side is the same as that for the LH side.

66. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE Removal

67. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Removal

68. REMOVE NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle) Removal

69. REMOVE NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle) Removal

70. REMOVE NO. 2 OIL COOLER TUBE CLAMP (for Automatic Transaxle) Removal

71. REMOVE TRANSMISSION OIL LEVEL GAGE SUB-ASSEMBLY (for Automatic Transaxle)

72. SEPARATE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transaxle) Removal

73. REMOVE IGNITION COIL ASSEMBLY Removal

74. REMOVE RADIO SETTING CONDENSER Removal

75. REMOVE NO. 2 VENTILATION HOSE Removal

76. REMOVE HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) Removal

77. REMOVE HEATER WATER HOSE INLET A Removal

78. REMOVE NO. 1 RADIATOR HOSE Removal

79. REMOVE INTAKE MANIFOLD Removal

80. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY Removal

81. REMOVE NO. 1 DELIVERY PIPE SPACER Removal

82. REMOVE INJECTOR VIBRATION INSULATOR Removal

83. REMOVE FUEL INJECTOR ASSEMBLY Removal

84. REMOVE GENERATOR ASSEMBLY Removal

85. REMOVE FAN BELT ADJUSTING BAR Removal

86. REMOVE OIL LEVEL DIPSTICK

87. REMOVE OIL LEVEL GAGE GUIDE Removal

88. REMOVE WATER BY-PASS HOSE Removal

89. REMOVE WATER INLET HOSE Removal

90. REMOVE NO. 1 WATER BY-PASS PIPE Removal

91. REMOVE AIR TUBE ASSEMBLY Removal

92. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Removal

93. REMOVE MANIFOLD STAY Removal

94. REMOVE EXHAUST MANIFOLD Removal

95. REMOVE WIRE HARNESS CLAMP BRACKET Removal

96. REMOVE WATER INLET Removal

97. REMOVE THERMOSTAT Removal

98. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Disassembly

99. SET NO. 1 CYLINDER TO TDC / COMPRESSION Disassembly

100. REMOVE CRANKSHAFT PULLEY Disassembly

101. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Disassembly

102. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY Disassembly

103. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL Removal

104. REMOVE NO. 2 CHAIN VIBRATION DAMPER Disassembly

105. REMOVE CHAIN TENSIONER SLIPPER Disassembly

106. REMOVE NO. 1 CHAIN VIBRATION DAMPER Disassembly

107. REMOVE CHAIN SUB-ASSEMBLY Disassembly

108. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET Disassembly

109. 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.
* If the camshaft bearing cap bolts hare been loosened, reapply seal packing between the camshaft housing and cylinder head.
(c) Remove the 5 bearing caps.

HINT
Arrange the removed parts in the correct order.

110. REMOVE CAMSHAFT

(a) Remove the camshaft from the camshaft housing.





111. REMOVE NO. 2 CAMSHAFT

(a) Remove the No. 2 camshaft from the camshaft housing.





112. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

(a) Remove the 16 valve rocker arms.





HINT
Arrange the removed parts in the correct order.

113. REMOVE VALVE LASH ADJUSTER ASSEMBLY

(a) Remove the 16 valve lash adjusters from the cylinder head.





HINT
Arrange the removed parts in the correct order.

114. REMOVE NO. 1 CAMSHAFT BEARING

(a) Remove the 2 No. 1 camshaft bearings.





HINT
Arrange the removed parts in the correct order.

115. REMOVE NO. 2 CAMSHAFT BEARING

(a) Remove the 2 No. 2 camshaft bearings.





HINT
Arrange the removed parts in the correct order.

116. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

(a) Remove the 2 bolts.





(b) Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.





NOTICE:
Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

HINT
Tape the screwdriver tip before use.

117. REMOVE CYLINDER HEAD SUB-ASSEMBLY

(a) Using several steps, loosen and remove the 10 cylinder head bolts uniformly with a 10 mm bi-hexagon wrench in the sequence shown in the illustration.





(a) Remove the 10 cylinder head bolts and the plate washers.

NOTICE:
* Do not drop the washers into the cylinder head.
* Head warpage or cracking could result from removing bolts in the wrong order.
(b) Remove the cylinder head sub-assembly.

118. REMOVE CYLINDER HEAD GASKET

(a) Remove the cylinder head gasket from the cylinder block.