Removal

2AZ-FE ENGINE MECHANICAL: CYLINDER HEAD: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE Removal

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 RADIATOR SUPPORT OPENING COVER
4. REMOVE FRONT WHEEL RH
5. REMOVE NO. 1 ENGINE UNDER COVER
6. REMOVE FRONT FENDER APRON RH
7. REMOVE NO. 1 ENGINE COVER Removal

8. DRAIN ENGINE COOLANT Service and Repair

9. DRAIN ENGINE OIL Replacement

10. REMOVE AIR CLEANER CAP Removal

11. REMOVE THROTTLE BODY Removal

12. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY Removal

13. REMOVE INTAKE MANIFOLD Removal

14. REMOVE INTAKE MANIFOLD INSULATOR Removal

15. REMOVE FRONT EXHAUST PIPE Removal

16. REMOVE OIL DIPSTICK
17. REMOVE OIL DIPSTICK GUIDE

(a) Remove the bolt and guide.
(b) Remove the O-ring from the guide.
18. REMOVE MANIFOLD STAY

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

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

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

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

(b) Remove the 5 nuts, manifold converter and gasket.
22. DISCONNECT NO. 1 RADIATOR HOSE

(a) Disconnect the No. 1 radiator hose.
23. 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.
24. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH Removal

25. REMOVE FAN AND GENERATOR V BELT Removal

26. REMOVE GENERATOR ASSEMBLY

27. REMOVE ENGINE MOUNTING INSULATOR RH Removal

28. REMOVE IDLER PULLEY Removal

29. REMOVE IGNITION COIL ASSEMBLY Removal

30. REMOVE SPARK PLUG Adjustments

31. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Removal

32. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Removal

33. REMOVE CRANKSHAFT POSITION SENSOR Removal

34. REMOVE OIL PAN SUB-ASSEMBLY Removal

35. SET NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned.
(b) Check that each timing mark of the camshaft timing gear and sprocket is aligned with each timing mark 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.
36. REMOVE NO. 2 CAMSHAFT

(a) Place paint marks on the chain in alignment with the timing marks on the camshaft timing gear and camshaft timing sprocket.

(b) Remove the 2 nuts, tensioner and gasket.

(d) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
(e) Remove the 5 bearing caps.

(f) While holding the No. 2 camshaft by hand, remove the camshaft timing sprocket set bolt.
(g) Remove the camshaft timing sprocket from the No. 2 camshaft with the timing chain wrapped on the sprocket.
(h) Remove the camshaft timing sprocket from the timing chain.
37. REMOVE CAMSHAFT

(a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
(b) Remove the 5 bearing caps.
(c) Remove the camshaft and camshaft timing gear while holding the timing chain by hand.

(d) Tie the timing chain with a string as shown in the illustration.
NOTE: Be careful not to drop anything inside the timing chain cover.

38. REMOVE CRANKSHAFT PULLEY Removal

39. REMOVE ENGINE MOUNTING BRACKET RH Removal

40. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY Removal

41. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE
42. REMOVE TIMING CHAIN GUIDE Removal

43. REMOVE CHAIN TENSIONER SLIPPER Removal

44. REMOVE NO. 1 CHAIN VIBRATION DAMPER Removal

45. REMOVE CHAIN SUB-ASSEMBLY
46. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Removal

47. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

(a) Clamp the camshaft in a vise, and make sure that the camshaft timing gear does not rotate.
(b) Cover all the oil ports with vinyl tape except the advance side port shown in the illustration.

(c) Apply air pressure of 100 kPa (1.0 kgf/cm2, 14 psi) to the oil path, then turn the camshaft timing gear to the advance direction (counterclockwise) by hand.
CAUTION: Cover the paths with a shop rag to avoid oil splashes.
HINT: Depending on the air pressure, the camshaft timing gear will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure is difficult to apply because of air leakage from the port, there may be the case that the lock pin is difficult to release.

(d) Remove the flange bolt of the camshaft timing gear.
- Be sure not to remove the other 4 bolts.
- When reusing the camshaft timing gear, release the straight pin lock first, then install the gear.

48. REMOVE CYLINDER HEAD SUB-ASSEMBLY

(a) Using 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.
NOTE: 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.
NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

49. REMOVE CYLINDER HEAD GASKET