Part 1

PARTIAL ENGINE ASSEMBLY (2ZZ-GE)




















COMPONENTS

OVERHAUL
1. REMOVE OIL FILLER CAP SUB-ASSEMBLY





2. REMOVE OIL FILLER CAP GASKET
a. Using a screwdriver, remove the gasket from the oil filler cap.
3. REMOVE VENTILATION VALVE SUB-ASSEMBLY
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, then remove the cylinder head cover.





b. Remove the 4 spark plug tube gaskets and O-ring.
6. REMOVE CYLINDER HEAD COVER GASKET
a. Remove the cylinder head cover gasket from the cylinder head cover.





7. REMOVE WATER PUMP PULLEY
a. Using SST, remove the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00600)





8. REMOVE WATER PUMP ASSEMBLY
a. Remove the 6 bolts, then remove the water pump.
b. Remove the O-ring from the timing chain cover.





9. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Remove the 4 bolts, then remove the engine mounting bracket.





10. SET NO.1 CYLINDER TO TDC/COMPRESSION
a. Turn the crankshaft pulley until its groove and the timing chain cover are aligned.
b. Check that the point marks of the camshaft timing sprocket and the VVT timing sprocket are as shown in the illustration.

HINT: If not, turn the crankshaft 1 revolution (360°) to align the marks as above.





11. REMOVE CRANKSHAFT PULLEY
a. Using SST, remove the pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021





b. Using SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)





12. REMOVE CHAIN TENSIONER ASSEMBLY NO.1
a. Remove the 2 nuts, then remove the chain tensioner assembly No.1.

NOTICE: Do not to turn the crankshaft without the chain tensioner.





13. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove the 13 bolts and timing chain cover.
b. Remove the 2 gaskets from the timing chain cover.

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





14. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL
a. Place the timing chain cover on a wooden block.
b. Using a screwdriver, remove the timing chain cover oil seal.
15. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
16. REMOVE CHAIN TENSIONER SLIPPER
a. Remove the bolt, then remove the chain tensioner slipper.
17. REMOVE CHAIN VIBRATION DAMPER NO.1
a. Remove the 2 bolts, then remove the chain vibration damper No.1.





18. REMOVE CHAIN SUB-ASSEMBLY
a. Using 2 screwdrivers, pry out the chain together with the crankshaft timing gear as shown in the illustration.

NOTICE: 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.





19. REMOVE OIL PUMP ASSEMBLY
a. Remove the 5 bolts, then remove the oil pump.
b. Remove the gasket from the cylinder block.





20. REMOVE CAMSHAFT
a. Using several steps, uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.
b. Remove the 2 camshafts from the cylinder head.





21. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET
a. Clamp the No.2 camshaft in a vise, then remove the camshaft timing gear.

NOTICE: Be careful not to damage the camshaft.





22. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
a. Check the lock of camshaft timing gear.
(1) Clamp the camshaft in a vise, then confirm that the camshaft timing gear is locked.

NOTICE: Be careful not to damage the camshaft.

b. Check that the camshaft timing gear assembly does not rotate.

NOTICE: Do not damage the camshaft by clamping it in a vise too tightly.

c. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

HINT: One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the 2 oil paths for each groove with a piece of rubber before wrapping the cam journal with tape.

d. Puncture the tape over the advance side path and retard side path on the opposite side of the groove.





e. Apply approximately 150 kPa (1.5 kgf/cm2) of air pressure to the retard side oil path.

NOTICE: When applying air pressure, cover the paths with a shop rag to prevent oil splashes.

f. Apply approximately 150 kPa (1.5 kgf/cm2) of air pressure to the advance side oil path.





g. Confirm that the camshaft timing gear assembly revolves in the advance direction when the air pressure on the retard side path is reduced.

HINT:
^ If the timing gear assembly does not revolve in the advance direction by air pressure, turn it forcibly by hand after air pressure is applied to both oil paths. When revolving, first turn it in the retard direction, then in the advance direction.
^ The lock pin is released, and the camshaft timing gear revolves in the advance direction.

h. When the camshaft timing gear assembly comes to the most advanced position, release the air pressure on the retard side path, then release the air pressure on the advance side path.

NOTICE: If the air pressure on the advance side path is released first, the camshaft timing gear assembly occasionally shifts abruptly in the retard direction. This may cause breakage of the lock pin. Be sure to release the air pressure on the retard side path first.





i. Remove the bolt and camshaft timing gear assembly.

NOTICE:
^ Do not remove the other 4 bolts.
^ When reusing the camshaft timing gear assembly, unlock the lock pin inside the camshaft timing gear first.





23. REMOVE CAM TIMING CONTROL VALVE HOUSING
a. Remove the 3 bolts and 2 nuts, then remove the cam timing control valve housing.
b. Remove the gasket.
24. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY





25. REMOVE OIL CONTROL VALVE FILTER
a. Remove the plug and oil control valve filter. (Front side)





b. Remove the oil control valve filter. (Rear side)





26. REMOVE VALVE ROCKER SHAFT SUB-ASSEMBLY NO.1
a. Remove the bolt, then remove the rocker shaft No.1
b. Remove the valve rocker arm.





27. REMOVE VALVE ROCKER SHAFT SUB-ASSEMBLY NO.2
a. Remove the bolt, then remove the rocker shaft No.2.
b. Remove the valve rocker arm.





28. REMOVE HEAD SUB-ASSEMBLY, CYLINDER
a. Using a bi-hexagon wrench 10, uniformly loosen the 10 cylinder head bolts, in several passes in the sequence shown.
b. Remove the 10 cylinder head bolts and 10 plate washers.

NOTICE:
^ Be careful not to drop the washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in the wrong order.

c. Remove the cylinder head from the cylinder block.
29. REMOVE CYLINDER HEAD GASKET





30. REMOVE OIL FILTER SUB-ASSEMBLY
a. Using SST, remove the oil filter.
SST 09228-06501
31. REMOVE OIL FILTER UNION
a. Using a socket hexagon wrench 12, remove the oil filter union.





32. REMOVE ENGINE REAR OIL SEAL
a. Using a knife, cut off the oil seal lip.
b. Using a screwdriver with its tip taped, pry out the oil seal.

NOTICE: After removing, check the crankshaft for damage. If damaged, smooth the surface with a 400-grit sandpaper.

33. REMOVE OIL PAN DRAIN PLUG
a. Remove the oil pan drain plug and gasket from the oil pan.





34. REMOVE OIL PAN SUB-ASSEMBLY
a. Remove the 12 bolts and 4 nuts.





b. Insert the blade of SST between the bearing cap and oil pan, then cut off the applied sealer and remove the oil pan.
SST 09032-00100

NOTICE: Be careful not to damage the oil pan surface which is in contact with the bearing cap and oil pan flange.

35. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the bolt and 2 nuts, then remove the oil strainer.
b. Remove the gasket.
36. REMOVE OIL PAN BAFFLE PLATE
a. Remove the 4 bolts, then remove the oil pan baffle plate.





37. INSPECT CHAIN TENSIONER ASSEMBLY NO.1
a. Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.
b. Release the ratchet pawl, then check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.





38. INSPECT CHAIN SUB-ASSEMBLY
a. Using a spring tension gauge and vernier calipers, pull the timing chain to 140 N (14.3 kgf, 31.5 lb), then measure its length.
Maximum chain elongation: 115.3 mm (4.539 inch)
If the elongation is greater than maximum, replace the chain.

HINT: Take the same measurements by pulling at 3 or more places selected at random.





39. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
a. Wrap the chain around the timing sprocket.
b. Using vernier calipers, measure the timing sprocket diameter with the chain.
Minimum gear diameter (w/ chain): 96.8 mm (3.811 inch)

NOTICE: The vernier calipers must be in contact with the chain rollers when measuring.

If the gear diameter is less than minimum, replace the chain and camshaft timing gear.





40. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
a. Wrap the chain around the timing sprocket.
b. Using vernier calipers, measure the timing sprocket diameter with the chain.
Minimum gear diameter (w/ chain): 51.0 mm (2.008 inch)

NOTICE: The vernier calipers must be in contact with the chain rollers when measuring.

If the gear diameter is less than minimum, replace the chain and crankshaft timing gear.





41. INSPECT CHAIN TENSIONER SLIPPER
a. Using vernier calipers, measure the chain tensioner slipper wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than maximum, replace the chain tensioner slipper.





42. INSPECT CHAIN VIBRATION DAMPER NO.1
a. Using vernier calipers, measure the vibration damper wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than maximum, replace the chain vibration damper.





43. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the length of the head bolts from the seat to the end.
Standard bolt length: 146.8 to 148.2 mm (5.780 to 5.835 inch)
Maximum bolt length: 148.5 mm (5.846 inch)
If the bolt length is greater than maximum, replace the cylinder head set bolt.





44. INSPECT VALVE ROCKER SHAFT SUB-ASSEMBLY NO.1
a. Using a micrometer, measure the rocker shaft No.1 diameter.
Standard diameter: 15.965 to 15.985 mm (0.6285 to 0.6293 inch)
If the diameter is less than minimum, replace the valve rocker shaft No.1.





45. INSPECT VALVE ROCKER SHAFT SUB-ASSEMBLY NO.2
a. Using a micrometer, measure the rocker shaft No.2 diameter.
Standard diameter: 15.965 to 15.985 mm (0.6285 to 0.6293 inch)
If the diameter is less than minimum, replace the valve rocker shaft No.2.





46. INSPECT VALVE ROCKER ARM
a. Cover the oil paths of the rocker arm shaft except 2 paths with vinyl type.
b. Align the oil path of the rocker arm shaft with the oil path of the rocker arm.
c. Check that the piston inside of the rocker arm moves when 180 kPa (1.8 kgf/cm2, 25.6 psi) of air is applied to the oil paths.





47. INSPECT CAMSHAFT SUB-ASSEMBLY, NO.1
a. Check the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at the center of the journal.
Maximum circle runout: 0.03 mm (0.0012 inch)
If the circle runout is greater than maximum, replace the camshaft.





b. Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe height.





Standard cam lobe height





Minimum cam lobe height

If the cam lobe height is less than minimum, replace the camshaft.





c. Inspect the camshaft journals.
(1) Using a micrometer, measure the journal diameter.
No.1 journal diameter: 34.449 to 34.465 mm (1.3563 to 1.3569 inch)
Other journal diameter: 27.949 to 27.965 mm (1.1004 to 1.1010 inch)
If the journal diameter is not as specified, check the oil clearance.





48. INSPECT CAMSHAFT SUB-ASSEMBLY, NO.2
a. Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
40.019 to 40.119 mm (1.5755 to 1.5795 inch) for No.1
38.863 to 38.963 mm (1.5300 to 1.5340 inch) for No.2
Minimum cam lobe height:
39.86 mm (1.5693 inch) for No.1
38.71 mm (1.5240 inch) for No.2
If the cam lobe height is less than minimum, replace the camshaft.





b. Inspect the camshaft journals.
(1) Using a micrometer, measure the journal diameter.
No.1 journal diameter: 34.449 to 34.465 mm (1.3563 to 1.3569 inch)
Other journal diameter: 27.949 to 27.965 mm (1.1004 to 1.1010 inch)
If the journal diameter is not as specified, check the oil clearance.
49. INSTALL OIL PAN BAFFLE PLATE
a. Install the oil pan baffle plate with the 4 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
50. INSTALL OIL STRAINER SUB-ASSEMBLY
a. Install a new gasket onto the oil pan baffle plate.
b. Install the oil strainer with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





51. INSTALL OIL PAN SUB-ASSEMBLY
a. Remove any old packing material from the contact surface.
b. Apply a continuous bead of seal packing (Diameter 4 to 5 mm (0.15748 to 0.19685 inch)) to the oil pan mating surface as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 3 minutes of applying seal packing.
^ Do not put in engine oil for at least 2 hours after installation.





c. Install the oil pan with the 12 bolts and 4 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
52. INSTALL OIL PAN DRAIN PLUG
a. Place a new gasket on the drain plug, then install it onto the oil pan.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)