8ZR-FXE ENGINE MECHANICAL  ENGINE UNIT  DISASSEMBLY  

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

1.51,1.073 1.656,1.802 1.656,1.802 1.896,1.802 false 1.969,1.719 2.281,1.917 0.313,0.198 10 false *a

*a	Protective Tape

Using a screwdriver with its tip wrapped with protective tape, remove the oil filler cap gasket from the oil filler cap sub-assembly.

Remove the 16 bolts and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

Remove the 2 gaskets from the camshaft bearing cap.

NOTICE:

As the gaskets may stick to the cylinder head cover sub-assembly, be careful not to drop any of the gaskets into the engine when removing the cylinder head cover sub-assembly.

Remove the 3 cylinder head cover gaskets from the cylinder head cover sub-assembly.

1.115,0.896 1.531,0.479 true 1.594,0.354 1.906,0.51 0.313,0.156 10 true *a

*a	Protective Tape

Using a screwdriver as shown in the illustration, deform each spark plug tube gasket inwards and remove the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.

0.385,1.125 0.646,1.125 0.646,1.125 0.958,1.49 true 0.323,2.458 0.5,2.458 0.5,2.458 0.844,3.135 true 0.323,4.031 0.479,4.031 0.479,4.031 0.677,3.406 true 0.667,1.802 0.667,2.438 0.667,2.438 1.708,2.438 true 2.979,2.427 2.823,2.427 2.823,2.427 2.646,1.677 true 1.396,2.427 1.396,1.833 true 0.156,2.385 0.469,2.583 0.313,0.198 10 false *a 0.156,3.948 0.469,4.146 0.313,0.198 10 false *b 0.219,1.052 0.531,1.25 0.313,0.198 10 false *c 1.75,2.365 2.063,2.563 0.313,0.198 10 false *d 3.031,2.354 3.344,2.552 0.313,0.198 10 false *a

*a	Timing Mark
*b	Timing Notch
*c	Timing Mark (Rectangle)
*d	Mark (Circle)

Turn the crankshaft pulley until its timing notch is aligned with timing mark "0" of the timing chain cover sub-assembly.

HINT:

There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

Remove the 2 nuts, bracket, No. 1 chain tensioner assembly and gasket from the timing chain cover sub-assembly.

NOTICE:

Do not turn the crankshaft without the No. 1 chain tensioner assembly installed.

Remove the No. 1 taper screw plug.

Using a 12 mm hexagon socket wrench, remove the oil filter union from the oil filter bracket.

Remove the 3 bolts and engine mounting bracket RH from the timing chain cover sub-assembly.

Remove the 4 bolts and oil filter bracket from the timing chain cover sub-assembly.

Remove the 2 oil filter bracket O-rings from the timing chain cover sub-assembly.

1.542,2.573 1.542,2.26 true 1.469,2.625 1.708,2.781 0.24,0.156 10 true *1

*1	Seal Washer

Remove the 18 bolts and seal washer from the timing chain cover sub-assembly.

2.688,1.344 0.354,2 0.354,2 0.5,0.531 true 2.615,3.906 0.354,2 0.354,2 0.656,3.531 true 0.146,1.927 0.458,2.083 0.313,0.156 10 false *a

*a	Protective Tape

Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly with a screwdriver with its tip wrapped with protective tape.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly, stiffening crankcase assembly and timing chain cover sub-assembly.

Remove the 3 O-rings from the cylinder head sub-assembly and cylinder block sub-assembly.

Remove the 3 bolts and engine water pump assembly from the timing chain cover sub-assembly.

Remove the gasket from the engine water pump assembly.

Using a 10 mm hexagon socket wrench, remove the 2 oil filter bracket with head straight screw plugs and 2 gaskets from the oil filter bracket.

Remove the chain tensioner slipper from the cylinder block sub-assembly.

Remove the 2 bolts and No. 1 chain vibration damper from the cylinder block sub-assembly and cylinder head sub-assembly.

Remove the 2 bolts and No. 2 chain vibration damper from the camshaft housing sub-assembly.

Remove the crankshaft timing sprocket from the crankshaft.

0.938,1.021 0.469,1.542 0.469,1.542 1.771,1.573 true 0.49,1.531 1.156,1.396 true 0.177,1.49 0.635,1.688 0.458,0.198 10 false SST

Using SST, hold the crankshaft pulley. Then remove the oil pump drive shaft gear nut.

SST

09213-58014  (91551-80840)
09330-00021  

0.573,1.438 1.229,1.438 false 1.042,1.198 1.698,1.198 true 0.354,1.385 0.667,1.542 0.313,0.156 10 false *1 0.844,1.135 1.156,1.292 0.313,0.156 10 false *2

*1	Chain Tensioner Plate
*2	Chain Damper Spring

Remove the bolt, chain tensioner plate and chain damper spring.

0.771,1.656 1.219,1.656 false 0.469,2.083 0.698,2.083 false 0.729,2.958 0.958,2.958 false 0.594,1.604 0.906,1.76 0.313,0.156 10 false *1 0.271,2.01 0.583,2.167 0.313,0.156 10 false *2 0.531,2.896 0.844,3.052 0.313,0.156 10 false *3

*1	No. 2 Chain Sub-assembly
*2	Oil Pump Drive Gear
*3	Oil Pump Drive Shaft Gear

Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain sub-assembly.

Remove the No. 1 crankshaft position sensor plate from the crankshaft.

0.885,1.781 1.146,1.208 false 0.802,1.802 1.115,1.958 0.313,0.156 10 false *a

*a	Protective Tape

Using a screwdriver with its tip wrapped with protective tape, remove the 2 crankshaft timing gear keys from the crankshaft.

2.802,1.625 2.708,0.906 true 0.875,1.469 1.323,1 true 1.458,0.958 0.885,0.281 0.885,0.281 2.781,0.76 true 2.74,1.667 3.052,1.823 0.313,0.156 10 true *a 0.719,0.188 1.031,0.344 0.313,0.156 10 false *b 0.719,1.51 1.031,1.667 0.313,0.156 10 true *c

*a	Adhesive Tape Sealing Area
*b	Prick a hole
*c	Adhesive Tape

After cleaning the VVT oil hole in the intake side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

NOTICE:

Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

Apply approximately 150 kPa (1.5 kgf/cm², 22 psi) of air pressure to the hole pricked in procedure A to release the lock pin.

NOTICE:

·

If air leaks out, reattach the adhesive tape.

·

Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

Turn the camshaft timing gear assembly within its movable range (30 to 32°) 2 or 3 times without turning it to the most retarded position. Make sure that the camshaft timing gear assembly turns smoothly.

NOTICE:

·

Do not lock the camshaft timing gear assembly.

·

If camshaft timing gear assembly is locked, release the lock pin again.

Using a wrench to hold the hexagonal portion of the camshaft, remove the bolt and camshaft timing gear assembly.

NOTICE:

1.021,1.104 0.563,1.146 0.563,1.146 1.24,0.938 true 1.229,1.552 0.583,1.156 0.583,1.156 1.417,1.375 true 0.365,1.083 0.677,1.24 0.313,0.156 10 false *a

*a	Do Not Remove

·

Before removing the camshaft timing gear assembly, make sure that the lock pin has been released.

·

Be sure not to remove the other 4 bolts.

·

Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.

Using a wrench to hold the hexagonal portion of the No. 2 camshaft, remove the bolt and camshaft timing sprocket.

0.344,0.354 0.5,0.552 0.156,0.198 10 true 1 0.396,1.635 0.552,1.833 0.156,0.198 10 true 2 0.969,0.281 1.125,0.479 0.156,0.198 10 true 5 1.031,1.698 1.188,1.896 0.156,0.198 10 true 6 1.573,0.25 1.729,0.448 0.156,0.198 10 true 9 1.563,1.698 1.823,1.979 0.26,0.281 10 true 10 2.229,0.25 2.385,0.448 0.156,0.198 10 true 7 2.208,1.688 2.365,1.885 0.156,0.198 10 true 8 2.802,0.313 2.958,0.51 0.156,0.198 10 true 3 2.802,1.646 2.958,1.844 0.156,0.198 10 true 4

Uniformly loosen and remove the 10 bolts in the order shown in the illustration.

0.406,1.979 0.563,2.177 0.156,0.198 10 false 1 0.156,0.885 0.313,1.083 0.156,0.198 10 false 3 0.344,0.042 0.5,0.24 0.156,0.198 10 false 2 1.021,0.083 1.177,0.281 0.156,0.198 10 false 8 1.042,1.927 1.177,2.115 0.135,0.188 10 false 7 1.583,1.948 1.833,2.167 0.25,0.219 10 false 13 2.177,1.927 2.427,2.146 0.25,0.219 10 false 10 2.75,1.896 2.927,2.094 0.177,0.198 10 false 4 2.802,0.125 3.021,0.365 0.219,0.24 10 false 5 1.542,0.083 1.792,0.302 0.25,0.219 10 false 14 2.146,0.104 2.396,0.323 0.25,0.219 10 false 11 2.906,0.813 3.063,1.01 0.156,0.198 10 true 6 0.698,0.719 0.854,0.917 0.156,0.198 10 true 9 1.26,0.646 1.51,0.865 0.25,0.219 10 true 15 2.427,0.729 2.677,0.948 0.25,0.219 10 true 12

Uniformly loosen and remove the 15 bolts in the order shown in the illustration.

NOTICE:

Make sure that the camshaft and No. 2 camshaft remain level while uniformly loosening the bolts.

Remove the camshaft from the camshaft housing sub-assembly.

Remove the 16 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

Remove the 16 valve stem caps from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

Remove the oil control valve filter from the No. 1 camshaft bearing cap.

Remove the 2 No. 1 camshaft bearings from the No. 1 camshaft bearing cap.

Remove the 2 No. 2 camshaft bearings from the camshaft housing sub-assembly.

3.063,1.177 3.219,1.375 0.156,0.198 10 false 1 0.427,0.146 0.583,0.344 0.156,0.198 10 false 2

Remove the 2 bolts from the camshaft housing sub-assembly.

0.51,3.208 0.927,3.958 0.927,3.958 2,3.625 true 0.854,4 1.167,4.156 0.313,0.156 10 false *a

*a	Protective Tape

Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver with its tip wrapped with protective tape.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head sub-assembly and camshaft housing sub-assembly.

0.708,1.813 0.865,2.01 0.156,0.198 10 true 1 0.698,0.271 0.854,0.469 0.156,0.198 10 true 3 1.177,0.271 1.333,0.469 0.156,0.198 10 true 7 1.188,1.802 1.344,2 0.156,0.198 10 true 5 1.677,0.281 1.833,0.479 0.156,0.198 10 true 9 1.646,1.802 1.896,2.042 0.25,0.24 10 true 10 2.146,0.26 2.302,0.458 0.156,0.198 10 true 6 2.146,1.802 2.302,2 0.156,0.198 10 true 8 2.646,0.26 2.802,0.458 0.156,0.198 10 true 2 2.635,1.781 2.792,1.979 0.156,0.198 10 true 4

Using a 10 mm bi-hexagon socket wrench, uniformly loosen and remove the 10 cylinder head set bolts and 10 cylinder head set plate washers in several steps in the order shown in the illustration.

NOTICE:

·

Do not drop the cylinder head set plate washers into the cylinder head sub-assembly.

·

Removing the cylinder head set bolts in the incorrect order may cause warpage or cracking of the cylinder head sub-assembly.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

Remove the 2 cylinder block water jacket spacers from the cylinder block sub-assembly.

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

2.177,1.802 2.49,1.958 0.313,0.156 10 false *a 0.208,1.656 0.521,1.813 0.313,0.156 10 false *a

*a

Nut

Remove the 10 bolts and 2 nuts from the No. 2 oil pan sub-assembly.

Insert the blade of an oil pan seal cutter between the stiffening crankcase assembly and No. 2 oil pan sub-assembly. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

NOTICE:

·

Be careful not to damage the surface of the No. 2 oil pan sub-assembly which contacts the stiffening crankcase assembly.

·

Be careful not to damage the flange of the stiffening crankcase assembly.

Uniformly loosen and remove the 11 bolts from the stiffening crankcase assembly.

0.396,3.635 0.396,4.323 0.396,4.323 1.344,3.479 true 2.594,4.188 3.146,4.417 3.146,4.417 3.146,2.979 true 0.333,4.354 0.646,4.51 0.313,0.156 10 false *a 3.083,4.438 3.396,4.594 0.313,0.156 10 false *a

*a	Protective Tape

Remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly with a screwdriver with its tip wrapped with protective tape.

NOTICE:

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

Remove the rear engine oil seal from the cylinder block sub-assembly.

NOTICE:

Be careful not to damage the crankshaft.