ENGINE MECHANICAL (VZFE) EM9 REMOVAL EM1MP01 1. REMOVE ENGINE UNDER COVER. DRAIN ENGINE COOLANT. REMOVE FRONT EXHAUST PIPE (See page EM10 ). DISCONNECT HEATER HOSE. REMOVE AIR CLEANER ASSEMBLY 6. REMOVE HIGHTENSION CORDS WITH IGNITION COILS AND SPARK PLUGS (See page IG ). DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY A168 8. DISCONNECT HOSES Remove the bolts from the air intake chamber assembly. A16 Disconnect the EVAP hose. A10 (d) (d) Disconnect the fuel return hose. Disconnect the fuel inlet hose. (e) A0 81
EM0 ENGINE MECHANICAL (VZFE) 9. REMOVE INTAKE CHAMBER STAY Remove the bolts and intake chamber stay. 10. REMOVE NO. TIMING BELT COVER (See page EM1 ) A16 (d) 11. REMOVE AIR INTAKE CHAMBER ASSEMBLY Disconnect the throttle position sensor connector. Disconnect the throttle control motor connector. Disconnect the accelerator pedal position sensor connector. (d) Disconnect the air hose. (e) Disconnect the water bypass hoses. (e) A166 (f) Remove the bolts, nuts, the air intake chamber assembly and gasket. A169 A06 1. REMOVE INTAKE AIR CONNECTOR ASSEMBLY Remove the bolt and disconnect the engine wire. Disconnect the fuel return hose. Disconnect the vacuum sensing hose form the fuel pressure regulator. (d) Remove the bolt and disconnect the ground strap from the intake air connector. (e) Disconnect the DLC1 from the bracket. (f) Remove the bolts, nuts, the intake air connector assembly and gasket. A16 8
ENGINE MECHANICAL (VZFE) EM1 1. DISCONNECT ENGINE WIRE PROTECTOR Disconnect the 6 injector connectors. Disconnect the ECT sensor connector. Disconnect the ECT sender gauge connector. (d) Disconnect the engine wire clamps. (e) Remove the bolts, and disconnect the engine wire protector from the cylinder head. A0 (f) Disconnect the engine wire clamps from the engine. 1. REMOVE FUEL PRESSURE REGULATOR (See page SF16 ) S011 1. REMOVE INTAKE MANIFOLD ASSEMBLY Remove the bolts and intake manifold stay. Remove the 8 bolts, nuts, plate washers, the intake manifold assembly and gaskets. 16. REMOVE TIMING BELT (See page EM1 ) S006 1. REMOVE CAMSHAFT POSITION SENSOR Disconnect the camshaft position sensor connector. Disconnect the clamp from the No. timing belt cover. Remove the bolt and camshaft position sensor. 18. REMOVE NO. TIMING BELT COVER Remove the 6 bolts and timing belt cover. 19. REMOVE GENERATOR (See page CH6 ) S00 8
EM ENGINE MECHANICAL (VZFE) 0. REMOVE GENERATOR BRACKET Remove the bolts and generator bracket insulator. Remove the bolts and generator bracket. S011 1. REMOVE PS PUMP BRACKET Remove the bolts and PS pump bracket.. REMOVE EXHAUST CROSSOVER PIPE Remove the 6 nuts, crossover pipe and gaskets.. REMOVE EXHAUST MANIFOLDS Remove the 1 nuts, exhaust manifolds and gaskets. S011 P1196. REMOVE COVERS Remove the 8 bolts, seal washers, cylinder head cover and gasket. Remove the cylinder head covers.. REMOVE CAMSHAFTS Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, these steps should be carried out. Remove the exhaust camshaft of the RH cylinder head. (1) Align the timing marks ( dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench. Z16 Dot Marks A098 8
ENGINE MECHANICAL (VZFE) EM SubGear Service Bolt Driven Gear () Secure the exhaust camshaft subgear to the main gear with a service bolt. Torque:. N m ( kgf cm, 9 in. lbf) Recommended service bolt: Thread diameter 6 mm Thread pitch 1.0 mm Z16 Bolt length 16 0 mm (0.6 0.9 in.) If the bolt is loose, the camshaft may tilt and cause damage in the camshaft and camshaft bearing cap. When removing the camshaft, make sure that the torsional spring force of the subgear has been eliminated by the above operation. 6 8 () Uniformly loosen and remove the 8 bearing cap bolts, in several passes, in the sequence shown. () Remove the bearing caps and exhaust camshaft. 1 A01 6 10 8 9 Remove the intake camshaft of the RH cylinder head. (1) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. () Remove the bearing caps, oil seal and intake camshaft. 1 A01 Remove the exhaust camshaft of the LH cylinder head. (1) Align the timing marks (1 dot mark) of the camshaft drive and driven gears by turning the camshaft with a wrench. 1 Dot Mark A086 8
EM ENGINE MECHANICAL (VZFE) SubGear Service Bolt Driven Gear A08 () Secure the exhaust camshaft subgear to the main gear with a service bolt. Torque:. N m ( kgf cm, 9 in. lbf) Recommended service bolt: Thread diameter Thread pitch Bolt length 6 mm 1.0 mm 16 0 mm (0.6 0.9 in.) If the bolt is loose, the camshaft may tilt and cause damage in the camshaft and camshaft bearing cap. When removing the camshaft, make sure that the torsional spring force of the subgear has been eliminated by the above operation. 6 8 () Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. () Remove the bearing caps and exhaust camshaft. 1 A016 A098 8 10 1 6 9 (d) Remove the intake camshaft of the LH cylinder head. (1) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. () Remove the bearing caps, oil seal and intake camshaft. Arrange the camshafts in the correct order. Arrange the bearing caps in the correct order. A01 A090 SST Turn 6. DISASSEMBLE EXHAUST CAMSHAFTS Mount the hexagonal wrench head portion of the camshaft in a vise. Be careful not to damage the camshaft. Using SST, turn the subgear clockwise and remove the service bolt. SST 0996010010 (099601000, 099600600) P68 86
ENGINE MECHANICAL (VZFE) EM Using snap ring pliers, remove the snap ring. (d) Remove the wave washer, camshaft subgear and camshaft gear spring. Arrange the camshaft subgears and gear springs (RH and LH side). P10 Recessed Head Bolt 8 mm Hexagon Wrench. REMOVE S Remove the bolt and disconnect the ground strap. Using an 8 mm hexagon wrench, remove the cylinder head (recessed head) bolt on each cylinder head, then repeat for the other side, as shown. Front Z1 1 Pointed Head Bolt Uniformly loosen nd remove the 8 cylinder head (1 pointed head) bolts on each cylinder head, in several passes, in the sequence shown, then repeat for the other side, as shown. Remove the 16 cylinder head bolts and plate washers. Head warpage or cracking could result from removing bolts in an incorrect order. Front 1 6 8 8 6 1 A018 8
EM6 ENGINE MECHANICAL (VZFE) P0088 (d) Lift the cylinder head from the dowels on the cylinder block and place the cylinder heads on wooden blocks on a bench. If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver. Arrange the cylinder heads in the correct order. Be careful not to damage the contact surfaces of the cylinder head and cylinder block. 88