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Home >> Toyota >> 2016 >> Corolla S, Standard Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Engine Mechanical (2ZR-FAE) - Service Information (2 Of 2) (Model Code: ZRE172)) >> Engine Unit >> Disassembly [08/2013 - 04/2014] >> Procedure

Disassembly [08/2013 - 04/2014]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
    1. Remove the oil filler cap sub-assembly.
      GTY432583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE OIL FILLER CAP GASKET 
    1. Remove the oil filler cap gasket.
      GTY288028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE ENGINE COVER JOINT 
    1. Remove the 2 engine cover joints.
      GTY432584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE SPARK PLUG 

    Refer to PROCEDURE - Step 3

  5. REMOVE CAMSHAFT POSITION SENSOR (NO. 1 CRANK POSITION SENSOR) 

    Refer to PROCEDURE - Step 2

  6. REMOVE VALVEMATIC SHAFT SENSOR (NO. 1 CRANK POSITION SENSOR) 

    Refer to PROCEDURE - Step 2

  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side) 

    Refer to PROCEDURE - Step 2

  8. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side) 

    Refer to PROCEDURE - Step 3

  9. REMOVE CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  10. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 1

  11. REMOVE KNOCK CONTROL SENSOR 

    Refer to PROCEDURE - Step 2

  12. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 4

  13. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 13 bolts, seal washer and cylinder head cover sub-assembly.
      GTY452313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 gaskets from the camshaft bearing cap.
      GTY429204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      As 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.

  14. REMOVE CYLINDER HEAD COVER GASKET 
    1. Remove the cylinder head cover gasket.
      GTY434674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE SPARK PLUG TUBE GASKET 
    1. Pry up the 4 claws of the ventilation baffle plate.
      GTY434683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not deform the claws of the ventilation baffle plate more than necessary.

    2. Remove the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.
      NOTE:

      Be careful not to damage the cylinder head cover sub-assembly.

      HINT: 

      Prevent the spark plug tube gaskets from being deformed as much as possible. The removed spark plug tube gaskets will be used when installing new spark plug tube gaskets.

  16. REMOVE OIL FILTER 

    Refer to PROCEDURE - Step 2

  17. REMOVE OIL FILTER UNION (for Oil Filter Sub-assembly Type) 
    GTY718990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a 12 mm hexagon socket wrench, remove the oil filter union from the oil filter bracket.
  18. SET NO. 1 CYLINDER TO TDC/COMPRESSION 

    Refer to PROCEDURE - Step 15

  19. REMOVE CRANKSHAFT PULLEY 

    Refer to PROCEDURE - Step 5

  20. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 18

  21. REMOVE STUD BOLT 
    NOTE:

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

    1. Remove the stud bolt from the engine mounting bracket RH.
      GTY426081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Remove the 3 bolts and engine mounting bracket RH.
      GTY422000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts and oil filter bracket.
      GTY420343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 O-rings.
      GTY433986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 19 bolts and seal washer.
      GTY449114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Washer
    5. 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 as shown in the illustration.
      GTY431626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Protective Tape
      NOTE:

      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.

      HINT: 

      Tape the screwdriver tip before use.

    6. Remove the 3 O-rings.
      GTY447514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 3 bolts and engine water pump assembly.
      GTY438133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the gasket.
      GTY438176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE TIMING CHAIN COVER OIL SEAL 
    1. Place the timing chain cover sub-assembly on wooden blocks.
      GTY428467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
      *b Protective Tape
    2. Using a screwdriver, tap out the timing chain cover oil seal.
      NOTE:

      Do not damage the surface of the timing chain cover oil seal press fit hole.

      HINT: 

      Tape the screwdriver tip before use.

  24. REMOVE WATER INLET HOUSING STUD BOLT 
    NOTE:

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

    1. Using an E5 "TORX" socket wrench, remove the 2 water inlet housing stud bolts.
      GTY454660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE WATER INLET HOUSING 
    1. Remove the 3 bolts, water inlet housing and gasket.
      GTY455906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 1 GENERATOR BRACKET 
    1. Remove the 4 bolts and No. 1 generator bracket.
      GTY449224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE CHAIN TENSIONER SLIPPER 

    Refer to PROCEDURE - Step 22

  28. REMOVE NO. 1 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 23

  29. REMOVE CHAIN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 24

  30. REMOVE CRANKSHAFT TIMING SPROCKET 
    1. Remove the crankshaft timing sprocket.
      GTY449126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE NO. 2 CHAIN SUB-ASSEMBLY 
    1. Temporarily install the crankshaft pulley and crankshaft pulley bolt.
      GTY439319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, hold the crankshaft pulley. Then remove the oil pump drive shaft gear nut.

      for 86 mm (3.39 in.) Bolt Pitch Type:

      • SST: 09330-0002109213-58014 
        1. 91551-80840

      for 64 mm (2.52 in.) Bolt Pitch Type:

      • SST: 09213-5401509330-00021 

      HINT: 

      For the 64 mm (2.52 in.) bolt pitch type, the part number of the installation bolt for SST (crankshaft pulley holding tool) is 91551-00850 (quantity: 2).

    3. Remove SST, the crankshaft pulley bolt and crankshaft pulley.
    4. Remove the bolt, chain tensioner plate and chain damper spring.
      GTY455886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain sub-assembly.
      GTY453929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Chain Sub-assembly
      *2 Oil Pump Drive Gear
      *3 Oil Pump Drive Shaft Gear
  32. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE 
    1. Remove the No. 1 crankshaft position sensor plate.
      GTY449127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE CRANKSHAFT TIMING GEAR KEY 
    1. Using a screwdriver, remove the 2 crankshaft timing gear keys.
      GTY436930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      HINT: 

      Tape the screwdriver tip before use.

  34. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 25

  35. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 26

  36. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 27

  37. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 28

  38. REMOVE VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 29

  39. INSTALL VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 30

  40. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 31

  41. REMOVE CONTINUOUSLY VARIABLE VALVE LIFT CONTROLLER ASSEMBLY 

    Refer to PROCEDURE - Step 10

  42. REMOVE CAMSHAFT HOUSING STUD BOLT 
    NOTE:

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

    1. Using an E7 "TORX" socket wrench, remove the 2 camshaft housing stud bolts.
      GTY426430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE CAMSHAFT HOUSING RING PIN 
    NOTE:

    It is not necessary to remove a camshaft housing straight pin unless it is being replaced.

  44. REMOVE CYLINDER HEAD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 14

  45. REMOVE CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 15

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

    Refer to PROCEDURE - Step 2

  47. REMOVE OIL PAN DRAIN PLUG 
    1. Remove the oil pan drain plug and gasket.
      GTY449115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Remove the 10 bolts and 2 nuts.
      GTY327135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the blade of an oil pan seal cutter between the stiffening crankcase assembly and No. 2 oil pan sub-assembly. Cut through the sealer and remove the No. 2 oil pan sub-assembly.
      GTY145991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • 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 stiffening crankcase assembly flange.
  49. REMOVE OIL PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 5

  50. REMOVE STIFFENING CRANKCASE ASSEMBLY 
    1. Uniformly loosen and remove the 11 bolts.
      GTY164808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly.
      GTY453051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

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

      HINT: 

      Tape the screwdriver tip before use.

  51. REMOVE NO. 1 TAPER SCREW PLUG 
    1. Remove the 2 No. 1 taper screw plugs.
      GTY293412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE STIFFENING CRANKCASE STUD BOLT 
    NOTE:

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

  53. REMOVE STIFFENING CRANKCASE RING PIN 
    NOTE:

    It is not necessary to remove a stiffening crankcase ring pin unless it is being replaced.

  54. REMOVE REAR ENGINE OIL SEAL 
    1. Remove the rear engine oil seal from the cylinder block sub-assembly.
      GTY220190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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