Removal

1ZZ-FE ENGINE MECHANICAL: CYLINDER HEAD:

COMPONENTS


























REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
(a) Discharge the fuel system pressure (Technician Safety Information).
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE FRONT WHEEL RH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the cylinder head cover No. 2 (Removal).
6. DRAIN ENGINE COOLANT
(a) Drain the engine coolant (Inspection).
7. SEPARATE EXHAUST PIPE ASSEMBLY FRONT
(a) Separate the exhaust pipe assembly front (Removal).
8. REMOVE MANIFOLD STAY
(a) Remove the manifold stay (Removal).
9. REMOVE FAN AND GENERATOR V BELT
(a) Remove the fan and generator V belt (Removal).
10. SEPARATE VANE PUMP ASSEMBLY
(a) Separate the vane pump assembly (Removal).
11. REMOVE GENERATOR ASSEMBLY
(a) Remove the generator assembly (Removal).
12. REMOVE ENGINE MOUNTING INSULATOR RH
(a) Remove the engine mounting insulator RH (Removal).
13. REMOVE IGNITION COIL ASSEMBLY
(a) Remove the ignition coil assembly (Removal).
14. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove the cylinder head cover sub-assembly (Removal).
15. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the V-ribbed belt tensioner assembly (Removal).
16. REMOVE ENGINE MOUNTING BRACKET RH
(a) Remove the engine mounting bracket RH (Removal).
17. REMOVE WATER PUMP ASSEMBLY
(a) Remove the water pump assembly (Removal).
18. SEPARATE CRANKSHAFT POSITION SENSOR
(a) Separate the crankshaft position sensor (Removal).
19. SET NO. 1 CYLINDER TO TDC / COMPRESSION
(a) Set the No. 1 cylinder to the TCD/compression (Removal).
20. REMOVE CRANKSHAFT PULLEY
(a) Remove the crankshaft pulley (Removal).
SST: 09960-10010
09962-01000
09963-01000
21. REMOVE CHAIN TENSIONER ASSEMBLY NO.1
(a) Remove the chain tensioner assembly No. 1 (Removal).
22. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
(a) Remove the timing chain or belt cover sub-assembly (Removal).
23. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL
(a) Remove the timing chain or belt cover oil seal (Removal).
24. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Remove the crankshaft position plate No. 1 (Removal).
25. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the chain tensioner slipper (Removal).
26. REMOVE CHAIN SUB-ASSEMBLY
(a) Remove the chain sub-assembly (Removal).
27. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the chain vibration damper No. 1 (Removal).
28. REMOVE AIR CLEANER HOSE NO.1





(a) Disconnect the VSV connector [A].
(b) Remove the clamp [B] of the engine wire.
(c) Disconnect the fuel vapor feed hose No. 1 [C] from the VSV.
(d) Disconnect the fuel vapor feed hose No. 3 [C] from the VSV.





(e) Loosen the 2 hose clamp bolts, then remove the air cleaner hose No. 1.
29. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY
30. REMOVE INTAKE MANIFOLD





(a) Remove the 2 clamps of the engine wire from the clamp bracket.





(b) Disconnect the throttle control motor connector.





(c) Disconnect the water by-pass hose [C] from the throttle body.
(d) Disconnect the water by-pass hose No. 2 [D] from the throttle body.





(e) Disconnect the union to check valve hose from the intake manifold.





(f) Remove the 4 bolts, 2 nuts and 2 clamp brackets.
(g) Remove the intake manifold and throttle body.
(h) Remove the gasket from the intake manifold.
31. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY





(a) Remove the bolt, then remove the camshaft timing oil control valve.
32. REMOVE CAMSHAFT





(a) Using several steps, uniformly loosen and remove the 19 bearing cap bolts in the sequence shown in the illustration.
(b) Remove the 9 bearing caps, then remove the 2 camshafts from the cylinder head.
33. DISCONNECT FUEL TUBE SUB-ASSEMBLY
(a) Disconnect the fuel tube sub-assembly (Removal).
SST: 09268-21010
34. REMOVE CYLINDER HEAD SUB-ASSEMBLY
(a) Disconnect the engine wire.





(1) Disconnect the 4 fuel injector connectors.





(2) Disconnect the oil pressure switch connector.





(3) Disconnect the crankshaft position sensor connector [A].
(4) Disconnect the knock sensor connector [B].





(5) Disconnect the camshaft position sensor connector.





(6) Disconnect the engine coolant temperature sensor connector [C].
(7) Disconnect the radio setting condenser connector [D].
(8) Disconnect the 2 engine earths [E].
(9) Remove the clamp [F] from the clamp bracket.
(10) Disconnect the heated oxygen sensor connector [G].





(b) Disconnect the radiator hose inlet [H].
(c) Disconnect the heater inlet water hose [I].
(d) Remove the bolt [J], then separate the water by-pass pipe No. 1.





(e) Using several steps, uniformly loosen and remove the 10 cylinder head bolts with a bi-hexagon wrench 10 mm in the sequence shown in the illustration. Remove the 10 cylinder head bolts and 10 plate washers.

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

(f) Remove the cylinder head.
35. REMOVE CYLINDER HEAD GASKET