Removal

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

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
Fuel System
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. REMOVE HOOD
(a) Disconnect the washer hose.

(b) Remove the 4 bolts and remove the hood.
4. REMOVE FRONT WHEEL RH
5. REMOVE NO. 1 ENGINE UNDER COVER
6. REMOVE REAR ENGINE UNDER COVER RH
7. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY Removal
8. DRAIN ENGINE COOLANT Service and Repair
9. DRAIN ENGINE OIL Replacement
10. SEPARATE CENTER EXHAUST PIPE ASSEMBLY Removal
11. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal
12. REMOVE WINDSHIELD WIPER ARM COVER Removal
13. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal
14. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal
15. REMOVE HOOD TO COWL TOP SEAL Removal
16. REMOVE COWL TOP VENTILATOR LOUVER RH Removal
17. REMOVE COWL TOP VENTILATOR LOUVER LH Removal
18. REMOVE FRONT WIPER MOTOR AND LINK Removal
19. REMOVE OUTER COWL TOP PANEL Removal
20. REMOVE FAN & GENERATOR V BELT Removal
21. REMOVE GENERATOR ASSEMBLY Removal

22. SEPARATE RADIATOR RESERVE TANK ASSEMBLY
(a) Separate the 2 bolts and radiator reserve tank.
23. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE Removal
24. REMOVE THROTTLE BODY ASSEMBLY Removal
25. REMOVE IGNITION COIL ASSEMBLY Removal
26. REMOVE SPARK PLUG Removal
27. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Removal
28. REMOVE OIL DIPSTICK
29. REMOVE OIL DIPSTICK GUIDE

(a) Remove the bolt and guide.
(b) Remove the O-ring from the guide.
30. DISCONNECT FUEL MAIN TUBE Removal
31. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY Removal
32. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Removal
33. REMOVE INTAKE MANIFOLD Removal
34. REMOVE INTAKE MANIFOLD INSULATOR Removal
35. REMOVE MANIFOLD STAY

(a) Remove the bolt, nut and stay.
36. REMOVE NO. 2 MANIFOLD STAY

(a) Remove the bolt, nut and stay.
37. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the 4 bolts and heat insulator.
38. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

(a) Disconnect the air-fuel ratio sensor connector.

(b) Remove the 5 nuts, manifold converter and gasket.
39. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

(a) Place a transmission jack underneath the engine, then put a wooden block on the jack.

(b) Remove the bolt and cooler bracket.

(d) Remove the 4 bolts and 2 nuts, then remove the engine mounting insulator RH.
NOTICE: Do not apply excessive force to the return tube when removing the engine mounting insulator RH.
HINT: Keep clearance by lowering the engine using the transmission jack when removing the front engine mounting insulator.

40. REMOVE FRONT ENGINE MOUNTING INSULATOR SUB-ASSEMBLY

(a) Remove the through bolt and nut.
(b) Remove the 2 bolts and front engine mounting insulator.
HINT: Keep clearance by lowering the engine using the transmission jack when removing the front engine mounting insulator.

41. REMOVE IDLER PULLEY SUB-ASSEMBLY

(a) Loosen the 2 bolts and remove the idler pulley with the 2 bolts.
42. REMOVE OIL PAN SUB-ASSEMBLY

(a) Install the No. 1 and No. 2 engine hangers with the new bolts.
Torque: 38 Nm (387 kgf-cm, 28 ft-lbf)

(b) Attach the sling device to the engine hangers and chain block.

(d) 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 or oil pan.

43. SET NO. 1 CYLINDER TO TDC / COMPRESSION

(a) Turn the crankshaft pulley until the groove and the timing mark "0" on the timing chain cover are aligned.
(b) Check that each timing mark on the camshaft timing gear and sprocket is aligned with the timing marks located on the No. 1 and No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft by 1 revolution (360°) to align the timing marks as above.
44. REMOVE CRANKSHAFT PULLEY Removal
45. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Remove the 2 nuts, chain tensioner and gasket.
NOTICE: Do not turn the crankshaft without the chain tensioner

46. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the 3 bolts and transverse engine engine mounting bracket.
47. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Lift the engine upward.
NOTICE: Do not lift the engine more than necessary.

(b) Remove the bolt, nut and V-ribbed belt tensioner.
48. REMOVE CRANKSHAFT POSITION SENSOR Removal
49. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

(a) Using an E10 "TORX" socket, remove the stud bolt for the V-ribbed belt tensioner.

(b) Remove the 12 bolts and 2 nuts.

(c) 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.

50. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

(a) Remove the No. 1 crankshaft position sensor plate.
51. REMOVE TIMING CHAIN GUIDE

(a) Remove the bolt and timing chain guide.
52. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the bolt and chain tensioner slipper.
53. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and chain vibration damper.
54. REMOVE CHAIN SUB-ASSEMBLY
55. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

(a) Remove the crankshaft timing gear or sprocket from the crankshaft.
56. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft 90° counterclockwise to align the adjusting hole on the oil pump drive shaft sprocket with the groove on the oil pump.

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

(c) Remove the bolt, chain tensioner plate and spring.
(d) Remove the oil pump drive sprocket, oil pump drive shaft sprocket and No. 2 chain.
57. DISCONNECT INLET RADIATOR HOSE Removal
58. DISCONNECT OUTLET HEATER WATER HOSE
59. DISCONNECT INLET HEATER WATER HOSE
60. DISCONNECT ENGINE WIRE

(a) Disconnect the radio setting condenser connector.
(b) Disconnect the engine oil pressure switch connector.
(c) Disconnect the engine coolant temperature sensor connector.
(d) Disconnect the camshaft position sensor connector.
(e) Remove the bolt and ground cable.
61. REMOVE NO. 2 CAMSHAFT Disassembly
62. REMOVE CAMSHAFT Disassembly
63. REMOVE NO. 1 CAMSHAFT BEARING Disassembly
64. REMOVE NO. 2 CAMSHAFT BEARING Disassembly
65. REMOVE CYLINDER HEAD SUB-ASSEMBLY

(a) In several steps, uniformly loosen and remove the 10 cylinder head bolts and 10 plate washers with a 10 mm bi-hexagon wrench in the sequence shown in the illustration.
NOTICE: Head warpage or cracking could result from removing the bolts in the wrong order.

(b) Using a screwdriver with its tip wrapped with tape, pry between the cylinder head and cylinder block, and remove the cylinder head.
NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

66. REMOVE CYLINDER HEAD GASKET