Part 1

1ZZ-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) Using a screwdriver, remove the gasket from the oil filler cap.
3. REMOVE VENTILATION VALVE SUB-ASSEMBLY

(a) Remove the ventilation valve from the cylinder head cover.
4. REMOVE SPARK PLUG

(a) Using a spark plug wrench, remove the 4 spark plugs.
5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove the 9 bolts, 2 seal washers and 2 nuts, then remove the cylinder head cover.
6. REMOVE CYLINDER HEAD COVER GASKET

(a) Remove the gasket from the cylinder head cover.
7. REMOVE ENGINE MOUNTING BRACKET RH

(a) Remove the 3 bolts, then remove the engine mounting bracket RH.
8. REMOVE WATER PUMP ASSEMBLY

(a) Remove the 6 bolts, then remove the water pump.
9. REMOVE WATER PUMP O-RING

(a) Remove the O-ring from the timing chain cover.
10. REMOVE CRANKSHAFT PULLEY

(a) Set the No. 1 cylinder to the TDC/compression.
(1) Turn the crankshaft pulley until its groove and timing mark "0" of the timing chain cover are aligned.
(2) Check that the point marks of the camshaft timing gears are in a straight line on the timing chain cover surface as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) to align the marks as above.

(b) Using SST, remove the crankshaft pulley bolt.
SST: 09960-10010
09962-01000
09963-01000
(c) Remove the crankshaft pulley from the crankshaft.
11. REMOVE CHAIN TENSIONER ASSEMBLY NO.1

(a) Remove the 2 nuts, then remove the chain tensioner.
12. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

(a) Remove the 10 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.

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

(a) Place the timing chain cover on wooden blocks.
(b) Using a screwdriver, remove the oil seal.
14. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1

(a) Remove the crankshaft position sensor plate from the crankshaft.
15. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the bolt, then remove the chain tensioner slipper.
16. REMOVE CHAIN SUB-ASSEMBLY

(a) Using 2 screwdrivers, pry out the chain with the crankshaft timing gear, as shown in the illustration.

- Use a shop rag to protect the engine.
- If revolving the camshafts with the chain off the gears, turn the crankshaft 1/4 revolution to prevent the valves from coming into contact with the pistons.

17. REMOVE CHAIN VIBRATION DAMPER NO.1

(a) Remove the 2 bolts, then remove the chain vibration damper.
18. REMOVE OIL PUMP ASSEMBLY

(a) Remove the 5 bolts, then remove the oil pump.
19. REMOVE OIL PUMP GASKET

(a) Remove the gasket from the cylinder block.
20. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Remove the bolt, then remove the camshaft timing oil control valve.
21. REMOVE OIL CONTROL VALVE FILTER

(a) Remove the bolt together with the gasket and oil control valve filter.
(b) Remove the gasket and oil control valve filter from the bolt.
22. REMOVE CAMSHAFT

(a) Using several steps, uniformly loosen and remove the 19 bearing cap bolts in the sequence shown in the illustration.
(b) Remove the 9 bearing caps, then remove the 2 camshafts from the cylinder head.
23. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET

(a) Clamp the camshaft in a vise, then remove the bolt and camshaft timing gear.

NOTE: Be careful not to damage the camshaft.