2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY; 2023 - 2025 MY Corolla Corolla HV [09/2022

Last Modified: 07-31-2024	6.11:8.1.0	Doc ID: RM10000000267JP
Model Year Start: 2023	Model: Corolla	Prod Date Range: [09/2022 - ]
Title: 2ZR-FXE (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY; 2023 - 2025 MY Corolla Corolla HV [09/2022 - ]

DISASSEMBLY

PROCEDURE

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

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

2. REMOVE OIL FILLER CAP GASKET

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

*a	Protective Tape

3. REMOVE SPARK PLUG

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4. REMOVE CAMSHAFT POSITION SENSOR

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5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

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6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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

(b) 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.

7. REMOVE CYLINDER HEAD COVER GASKET

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

8. REMOVE SPARK PLUG TUBE GASKET

(a) 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.

*a	Protective Tape

9. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

(a) 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.

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

(b) Check that the timing marks on both the camshaft timing sprocket and camshaft timing gear assembly are facing upward as shown in the illustration.

HINT:

If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as shown in the illustration.

10. REMOVE CRANKSHAFT PULLEY

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11. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a) 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.

12. REMOVE CRANKSHAFT POSITION SENSOR

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13. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

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14. REMOVE NO. 1 TAPER SCREW PLUG

(a) Remove the No. 1 taper screw plug.

15. REMOVE KNOCK CONTROL SENSOR

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16. REMOVE OIL FILTER SUB-ASSEMBLY

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17. REMOVE OIL FILTER UNION

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

18. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

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19. REMOVE TIMING CHAIN COVER OIL SEAL

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20. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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

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

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

*1	Seal Washer

(e) 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.

*a	Protective Tape

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

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

(h) Remove the gasket from the engine water pump assembly.

21. REMOVE OIL FILTER BRACKET WITH HEAD STRAIGHT SCREW PLUG

(a) 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.

22. REMOVE CHAIN TENSIONER SLIPPER

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

23. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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

24. REMOVE NO. 2 CHAIN VIBRATION DAMPER

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

25. REMOVE CHAIN SUB-ASSEMBLY

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26. REMOVE CRANKSHAFT TIMING SPROCKET

(a) Remove the crankshaft timing sprocket from the crankshaft.

27. REMOVE NO. 2 CHAIN SUB-ASSEMBLY

(a) Temporarily install the crankshaft pulley with the crankshaft pulley set bolt.

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

SST: 09213-58014

91551-80840

SST: 09330-00021

(d) Remove the bolt, chain tensioner plate and chain damper spring.

*1	Chain Tensioner Plate
*2	Chain Damper Spring

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

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

28. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

(a) Remove the No. 1 crankshaft position sensor plate from the crankshaft.

29. REMOVE CRANKSHAFT TIMING GEAR KEY

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

*a	Protective Tape

30. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

(a) Check the lock of the camshaft timing gear assembly.

(b) 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.

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

(d) 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.

(e) Forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

HINT:

Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance.

(f) 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.

(g) Remove the adhesive tape from the No. 1 camshaft bearing cap.

31. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

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

NOTICE:

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.

*a	Do Not Remove

32. REMOVE CAMSHAFT TIMING SPROCKET

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

33. REMOVE CAMSHAFT BEARING CAP

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

(b) 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.

HINT:

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

34. REMOVE CAMSHAFT

(a) Remove the camshaft from the camshaft housing sub-assembly.

35. REMOVE NO. 2 CAMSHAFT

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36. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

(a) 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.

37. REMOVE VALVE LASH ADJUSTER ASSEMBLY

(a) 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.

38. REMOVE VALVE STEM CAP

(a) 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.

39. REMOVE OIL CONTROL VALVE FILTER

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

40. REMOVE NO. 1 CAMSHAFT BEARING

(a) Remove the 2 No. 1 camshaft bearings from the No. 1 camshaft bearing cap.

41. REMOVE NO. 2 CAMSHAFT BEARING

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

42. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

(a) Remove the 2 bolts from the camshaft housing sub-assembly.

(b) 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.

*a	Protective Tape

43. REMOVE CYLINDER HEAD SUB-ASSEMBLY

(a) 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.

(b) Remove the cylinder head sub-assembly from the cylinder block sub-assembly.

44. REMOVE CYLINDER HEAD GASKET

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45. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

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46. REMOVE OIL PAN DRAIN PLUG

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

47. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

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

Nut

(b) 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.

48. REMOVE ENGINE OIL LEVEL SENSOR

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49. REMOVE OIL PUMP ASSEMBLY

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50. REMOVE STIFFENING CRANKCASE ASSEMBLY

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

(b) 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.

*a	Protective Tape

51. REMOVE REAR ENGINE OIL SEAL

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

NOTICE:

Be careful not to damage the crankshaft.

52. REMOVE STUD BOLT

NOTICE:

If a stud bolt is deformed or its threads are damaged, replace it.

53. REMOVE RING PIN

NOTICE:

It is not necessary to remove ring pins unless they are being replaced.