2NZ-FE ENGINE MECHANICAL  ENGINE UNIT  DISASSEMBLY  


PROCEDURE

Hide 89615 2.REMOVE KNOCK CONTROL SENSOR

Click hereEngine / Hybrid System>2NZ-FE ENGINE CONTROL>KNOCK SENSOR>REMOVAL

Hide 83530 3.REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

Click hereEngine / Hybrid System>2NZ-FE LUBRICATION>OIL PRESSURE SWITCH>REMOVAL

Hide 89422 4.REMOVE ENGINE COOLANT TEMPERATURE SENSOR

Click hereEngine / Hybrid System>2NZ-FE ENGINE CONTROL>ENGINE COOLANT TEMPERATURE SENSOR>REMOVAL

Hide 16321 5.REMOVE WATER INLET

Click hereEngine / Hybrid System>2NZ-FE COOLING>THERMOSTAT>REMOVAL

Hide 16331A 6.REMOVE THERMOSTAT

Click hereEngine / Hybrid System>2NZ-FE COOLING>THERMOSTAT>REMOVAL

Hide 12108 7.REMOVE OIL FILLER CAP SUB-ASSEMBLY

A130353

a.

Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.


Hide 12108A 8.REMOVE OIL FILLER CAP GASKET

a.
A301981C01
1.656,1.031 1.885,1.333 true 1.833,1.365 2.146,1.521 0.313,0.156 10 false *a
*a Protective Tape


Using a screwdriver, remove the oil filler cap gasket from the oil filler cap sub-assembly.

HINT:

Tape the screwdriver tip before use.



Hide 15100Q 9.REMOVE CRANKSHAFT POSITION SENSOR

Click hereEngine / Hybrid System>2NZ-FE ENGINE CONTROL>CRANKSHAFT POSITION SENSOR>REMOVAL

Hide 12204 10.REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

Click hereEngine / Hybrid System>2NZ-FE EMISSION CONTROL>PCV VALVE>REMOVAL

Hide 11201 11.REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

A066472C01
2.49,1 1.917,1.115 1.917,1.115 1.365,1.01 true 1.833,1.156 2.146,1.354 0.313,0.198 10 true *1
*1 Cylinder Head Cover Seal Washer


a.

Remove the 9 bolts, 2 nuts, 2 cylinder head cover seal washers and cylinder head cover sub-assembly.


Hide 11213 12.REMOVE CYLINDER HEAD COVER GASKET

a.

Remove the cylinder head cover gasket from the cylinder head cover sub-assembly.


Hide 11101J 13.REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

Click hereEngine / Hybrid System>2NZ-FE ENGINE CONTROL>CAMSHAFT OIL CONTROL VALVE>REMOVAL

Hide 11452 14.REMOVE OIL LEVEL DIPSTICK GUIDE

a.
A133601

Remove the bolt and oil level dipstick guide.


b.

Remove the O-ring from the oil level dipstick guide.


Hide 16173 15.REMOVE WATER PUMP PULLEY

Click hereEngine / Hybrid System>2NZ-FE COOLING>WATER PUMP>REMOVAL

Hide 13407 16.REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

a.
A116203C13
0.344,0.396 2.271,0.979 true 2.625,2.031 2.458,2.031 2.458,2.031 2.146,1.052 true 0.156,0.292 0.469,0.49 0.313,0.198 10 false *a 2.667,1.948 2.979,2.146 0.313,0.198 10 false *b
*a Timing Mark "0"
*b Timing Notch


Set the No. 1 cylinder to TDC/compression.

i.

Turn the crankshaft damper sub-assembly until its timing notch (groove) and the timing mark "0" of the oil pump assembly are aligned.


ii.
A116204C09
1.094,0.698 1.135,1.792 1.135,1.792 2.052,1.51 false 2.188,1.063 1.146,1.792 false 1.063,1.823 1.281,2.031 0.219,0.208 10 false *a
*a Timing Mark


Check that the timing marks on the camshaft timing sprocket and camshaft timing gear assembly are all facing upward as shown in the illustration.

HINT:

If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.




b.
A117461C01
1.188,0.385 0.667,0.563 0.667,0.563 1.115,0.802 false 0.344,0.479 0.896,0.844 0.552,0.365 10 false SST 2.396,1.979 2.708,2.135 0.313,0.156 10 false *a 0.156,1.469 0.469,1.625 0.313,0.156 10 false *b
*a Hold
*b Turn


Using SST, hold the crankshaft damper sub-assembly in place and loosen the crankshaft pulley set bolt.

SST
09213-14010  (91651-60865)
09330-00021  

NOTICE:

Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump assembly.



c.

Remove SST.


d.

Remove the crankshaft pulley set bolt and crankshaft damper sub-assembly.


Hide 12315A 17.REMOVE ENGINE MOUNTING BRACKET RH

A080957

a.

Remove the 4 bolts and engine mounting bracket RH.


Hide 16100 18.REMOVE ENGINE WATER PUMP ASSEMBLY

Click hereEngine / Hybrid System>2NZ-FE COOLING>WATER PUMP>REMOVAL

Hide 15100 19.REMOVE OIL PUMP ASSEMBLY

Click hereEngine / Hybrid System>2NZ-FE LUBRICATION>OIL PUMP>REMOVAL

Hide 15100C 20.REMOVE OIL PUMP SEAL

Click hereEngine / Hybrid System>2NZ-FE LUBRICATION>OIL PUMP>REMOVAL

Hide 13540 21.REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

A156302C06
1.677,0.604 1.063,0.604 false 1.656,0.438 1.125,0.198 false 0.896,0.521 1.281,0.917 0.385,0.396 10 false *a 0.948,0.104 1.26,0.333 0.313,0.229 10 false *1 1.896,0.198 2.219,0.51 0.323,0.313 10 false 40°
*1 Oil Jet
*a Timing Mark


NOTICE:
·

Do not rotate the crankshaft with the No. 1 chain tensioner assembly removed.

·

When rotating the camshaft with the chain sub-assembly removed, rotate the crankshaft counterclockwise 40° from TDC first, and align the oil jet hole with the timing mark. This prevents the pistons from coming into contact with the valves.



a.
A116564C02
1.677,2.594 1.677,2.958 true 1.615,2.979 1.948,3.271 0.333,0.292 10 false *a
*a Stopper Plate


Turn the stopper plate clockwise to release the lock.


b.
A116565C02
1.063,2.333 1.292,2.917 true 1.25,2.938 1.583,3.219 0.333,0.281 10 false *a
*a Plunger


With the lock released, push the plunger into the tensioner.


c.
A116566C02
1.708,2.646 1.708,2.958 true 1.646,2.979 2.01,3.281 0.365,0.302 10 false *a
*a Stopper Plate


Turn the stopper plate counterclockwise to set the lock.


d.
A116567C02
1.094,2.813 1.177,2.656 false 0.969,2.813 1.281,2.969 0.313,0.156 10 false *a
*a 3 mm Diameter Bar


Insert a 3 mm (0.118 in.) diameter bar into the hole of the stopper plate to lock the plunger.


e.
A116568

Remove the 2 bolts and No. 1 chain tensioner assembly.


Hide 13559 22.REMOVE CHAIN TENSIONER SLIPPER

A116569

a.

Remove the chain tensioner slipper.


Hide 13561 23.REMOVE NO. 1 CHAIN VIBRATION DAMPER

A116570

a.

Remove the 2 bolts and No. 1 chain vibration damper.


Hide 13506 24.REMOVE CHAIN SUB-ASSEMBLY

a.

Remove the chain sub-assembly from the camshaft timing gear assembly, camshaft timing sprocket and crankshaft.


Hide 23807 25.REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

Click hereEngine / Hybrid System>2NZ-FE FUEL>FUEL INJECTOR>REMOVAL

Hide 23807V 26.REMOVE NO. 1 DELIVERY PIPE SPACER

Click hereEngine / Hybrid System>2NZ-FE FUEL>FUEL INJECTOR>REMOVAL

Hide 23291 27.REMOVE INJECTOR VIBRATION INSULATOR

Click hereEngine / Hybrid System>2NZ-FE FUEL>FUEL INJECTOR>REMOVAL

Hide 23250 28.REMOVE FUEL INJECTOR ASSEMBLY

Click hereEngine / Hybrid System>2NZ-FE FUEL>FUEL INJECTOR>REMOVAL

Hide 11101E 29.REMOVE CAMSHAFT POSITION SENSOR

Click hereEngine / Hybrid System>2NZ-FE ENGINE CONTROL>CAMSHAFT POSITION SENSOR>REMOVAL

Hide 13512 30.REMOVE NO. 2 CAMSHAFT

A156302C06
1.677,0.604 1.063,0.604 false 1.656,0.438 1.125,0.198 false 0.896,0.521 1.281,0.917 0.385,0.396 10 false *a 0.948,0.104 1.26,0.333 0.313,0.229 10 false *1 1.896,0.198 2.219,0.51 0.323,0.313 10 false 40°
*1 Oil Jet
*a Timing Mark


NOTICE:
·

Do not rotate the crankshaft with the No. 1 chain tensioner assembly removed.

·

When rotating the camshaft with the chain sub-assembly removed, rotate the crankshaft counterclockwise 40° from TDC first, and align the oil jet hole with the timing mark. This prevents the pistons from coming into contact with the valves.



a.
A130358C02
0.729,0.5 0.729,0.219 true 1.104,0.563 1.104,0.281 true 1.625,0.573 1.625,0.292 true 2.135,0.563 2.135,0.281 true 2.656,0.563 2.656,0.281 true 0.521,0.052 0.948,0.229 0.427,0.177 10 false 1 *1 0.958,0.094 1.365,0.26 0.406,0.167 10 true 3 *2 1.469,0.094 1.875,0.26 0.406,0.167 10 true 5 *2 2.01,0.094 2.396,0.271 0.385,0.177 10 true 4 *2 2.51,0.104 2.948,0.281 0.438,0.177 10 true 2 *2
*1 No. 1 Camshaft Bearing Cap
*2 No. 2 Camshaft Bearing Cap


Uniformly loosen and remove the 11 bolts in the order shown in the illustration.

NOTICE:

Loosen each bolt uniformly while keeping the No. 2 camshaft level.



b.

Remove the No. 1 camshaft bearing cap, 4 No. 2 camshaft bearing caps and No. 2 camshaft.


Hide 13523 31.REMOVE CAMSHAFT TIMING SPROCKET

A301980

a.

Secure the No. 2 camshaft in a soft jaw vise.

NOTICE:

Do not damage the No. 2 camshaft.



b.

Remove the bolt and camshaft timing sprocket.


Hide 13511 32.REMOVE CAMSHAFT

A130360N01
1.104,1.677 1.104,1.417 true 1.625,1.688 1.625,1.427 true 2.135,1.698 2.135,1.438 true 2.656,1.698 2.656,1.438 true 1.063,1.75 1.219,1.948 0.156,0.198 10 false 2 1.604,1.75 1.76,1.948 0.156,0.198 10 false 4 2.125,1.75 2.281,1.948 0.156,0.198 10 false 3 2.635,1.75 2.792,1.948 0.156,0.198 10 false 1

a.

Uniformly loosen and remove the 8 bolts in the order shown in the illustration.

NOTICE:

Loosen each bolt uniformly while keeping the camshaft level.



b.

Remove the 4 No. 2 camshaft bearing caps and camshaft.


Hide 13050 33.REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

Click hereEngine / Hybrid System>2NZ-FE ENGINE MECHANICAL>CAMSHAFT>REMOVAL

Hide 11101 34.REMOVE CYLINDER HEAD SUB-ASSEMBLY

Click hereEngine / Hybrid System>2NZ-FE ENGINE MECHANICAL>CYLINDER HEAD GASKET>REMOVAL

Hide 15601 36.REMOVE OIL FILTER SUB-ASSEMBLY

Click hereEngine / Hybrid System>2NZ-FE LUBRICATION>OIL AND OIL FILTER>REPLACEMENT

Hide 15600A 37.REMOVE OIL FILTER UNION

A130443

a.

Using a 12 mm hexagon wrench, remove the oil filter union from the oil pan sub-assembly.


Hide 12102A 39.REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

a.
A265785

Remove the oil pan drain plug and gasket from the No. 2 oil pan sub-assembly.


b.

Remove the 9 bolts and 2 nuts.


c.
A088894

Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and No. 2 oil pan sub-assembly, cut through the applied seal packing and remove the No. 2 oil pan sub-assembly.

NOTICE:

Be careful not to damage the contact surfaces of the oil pan sub-assembly and No. 2 oil pan sub-assembly.



Hide 15104 40.REMOVE OIL STRAINER SUB-ASSEMBLY

a.
A133598

Remove the bolt, 2 nuts, oil strainer sub-assembly and oil strainer gasket from the oil pan sub-assembly.


Hide 12101 41.REMOVE OIL PAN SUB-ASSEMBLY

A301976

a.

Uniformly loosen and remove the 13 bolts.


b.
A130433C02
0.833,0.385 1.177,0.604 true 0.75,1.552 0.479,0.885 true 2.76,0.781 2.365,0.302 true 2.76,1.719 2.99,1.24 true 0.688,0.271 0.958,0.469 0.271,0.198 10 false *a 0.365,0.677 0.635,0.875 0.271,0.198 10 false *a 2.208,0.188 2.479,0.385 0.271,0.198 10 false *a 3.031,1.094 3.302,1.292 0.271,0.198 10 false *a
*a Protective Tape


Using a screwdriver, remove the oil pan sub-assembly by prying between the cylinder block sub-assembly and oil pan sub-assembly.

NOTICE:

Be careful not to damage the contact surfaces of the oil pan sub-assembly and cylinder block sub-assembly.


HINT:

Tape the screwdriver tip before use.



c.
A133599

Remove the 2 O-rings from the cylinder block sub-assembly.


Hide 15104E 42.REMOVE STUD BOLT

A117459

a.

Using an E5 "TORX" socket wrench, remove the 4 stud bolts.