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Disassembly [08/2013 - ]

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  1. REMOVE ENGINE COVER JOINT 
    1. Remove the 3 engine cover joints.
      Fig 1: Identifying Engine Cover Joints
      GTY319580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE SPARK PLUG  . Refer to REMOVAL [08/2013 - ] - Step 3
  3. REMOVE KNOCK CONTROL SENSOR  . Refer to REMOVAL [08/2013 - ] - Step 2
  4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR  . Refer to REMOVAL [08/2013 - ] - Step 5
  5. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY  . Refer to REMOVAL [08/2013 - ] - Step 1
  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY  . Refer to REMOVAL [08/2013 - ] - Step 2
  7. REMOVE CAMSHAFT POSITION SENSOR  . Refer to REMOVAL [08/2013 - ] - Step 2
  8. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
    1. Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.
  9. REMOVE OIL FILLER CAP GASKET 
    1. Remove the oil filler cap gasket from the oil filler cap sub-assembly.
  10. REMOVE CRANKSHAFT POSITION SENSOR  . Refer to REMOVAL [08/2013 - ] - Step 1
  11. REMOVE VENTILATION VALVE SUB-ASSEMBLY  . Refer to REMOVAL [08/2013 - ] - Step 2
  12. REMOVE VENTILATION CASE SUB-ASSEMBLY 
    1. Remove the 8 bolts and 2 nuts.
      Fig 2: Locating Ventilation Case Sub-Assembly & Fasteners
      GTY195361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the ventilation case sub-assembly by prying between the ventilation case sub-assembly and cylinder block sub-assembly with a screwdriver.
      Fig 3: Locating Contact Surfaces Of Cylinder Block & Ventilation Case
      GTY188620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

      HINT: 

      Tape the screwdriver tip before use.

  13. REMOVE SEPARATOR CASE 
    1. Remove the 2 bolts, separator case and gasket.
      Fig 4: Identifying Separator Case, Gasket & Bolts
      GTY183820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE CRANKSHAFT PULLEY 
    1. Using SST, hold the crankshaft pulley and loosen the pulley bolt. Further loosen the pulley bolt until 2 or 3 threads are screwed into the crankshaft.
      Fig 5: Removing Crankshaft Pulley
      GTY456121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
      • SST: 09213-54015 
      • SST: 09330-00021 

      HINT: 

      SST (Crankshaft pulley holding tool) Fixing bolt part No. : 91551-80650(2 pcs)

    2. Using SST and the pulley bolt, remove the crankshaft pulley.
      Fig 6: Removing Crankshaft Pulley
      GTY319834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Pulley Bolt
      *a Hold
      *b Turn
      • SST: 09950-50013 
        1. 09951-05010
        2. 09952-05010
        3. 09953-05020
        4. 09954-05011

      HINT: 

      Apply a lubricant to the threads and end of SST.

  15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.
      Fig 7: Identifying Cylinder Head Cover Sub-Assembly, Cylinder Head Cover Gasket Bolts & Washer
      GTY316230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 camshaft bearing cap oil hole gaskets.
      Fig 8: Identifying Gaskets
      GTY320433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE STUD BOLT 
    NOTE:

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

    1. Using an E6 "TORX" socket wrench, remove the 3 stud bolts from the cylinder head cover sub-assembly.
      Fig 9: Identifying Cylinder Head Cover Sub-Assembly Stud Bolts
      GTY322891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE SPARK PLUG TUBE GASKET 
    1. Using a screwdriver, pry out the 4 spark plug tube gaskets.
      Fig 10: Prying Out Spark Plug Tube Gaskets
      GTY323189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Tape
      NOTE:

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

      HINT: 

      Tape the screwdriver tip before use.

  18. REMOVE ENGINE MOUNTING BRACKET RH  . Refer to REMOVAL [08/2013 - ] - Step 6
  19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY  . Refer to REMOVAL [08/2013 - ] - Step 7
  20. REMOVE OIL PUMP RELIEF VALVE PLUG 
    1. Using a 14 mm hexagon wrench, remove the oil pump relief valve plug and gasket.
      Fig 11: Identifying Plug & Gasket
      GTY195056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TIMING CHAIN COVER PLATE 
    1. Remove the 4 bolts, timing chain cover plate and gasket.
      Fig 12: Locating Timing Chain Cover Plate Bolts
      GTY171214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE TIMING CHAIN COVER OIL SEAL  . Refer to REMOVAL [08/2013 - ] - Step 8
  23. SET NO. 1 CYLINDER TO TDC/COMPRESSION  See step  13
  24. REMOVE TIMING CHAIN GUIDE  See step  14
  25. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY  See step  15
  26. REMOVE CHAIN TENSIONER SLIPPER  See step  16
  27. REMOVE CHAIN SUB-ASSEMBLY 
    1. Remove the chain sub-assembly.
  28. REMOVE NO. 1 CHAIN VIBRATION DAMPER  See step  18
  29. REMOVE CRANKSHAFT TIMING SPROCKET 
    1. Remove the crankshaft timing sprocket from the crankshaft.
      Fig 13: Removing/Installing Crankshaft Timing Sprocket
      GTY195066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY  See step  19
  31. REMOVE CAMSHAFT TIMING SPROCKET  See step  20
  32. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY  See step  21
  33. REMOVE CAMSHAFT BEARING CAP  See step  22
  34. REMOVE OIL CONTROL VALVE FILTER 
    1. Remove the oil control valve filter from the No. 1 camshaft bearing cap.
      Fig 14: Removing/Installing Oil Control Valve Filter
      GTY179582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE CAMSHAFT  See step  25
  36. REMOVE NO. 1 CAMSHAFT BEARING 
    1. Remove the No. 1 camshaft bearing from the No. 1 camshaft bearing cap.
      Fig 15: View Of No. 1 Camshaft Bearing
      GTY195088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE NO. 2 CAMSHAFT BEARING 
    1. Remove the No. 2 camshaft bearing from the camshaft housing sub-assembly.
      Fig 16: View Of No. 2 Camshaft Bearing
      GTY195089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE STUD BOLT 
    NOTE:

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

    1. Using an E8 "TORX" socket wrench, remove the stud bolt from the camshaft housing sub-assembly.
      Fig 17: Identifying Camshaft Housing Sub-Assembly Stud Bolt
      GTY316356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN 
    NOTE:

    It is not necessary to remove the ring pin unless it is being replaced.

    1. Remove the 10 camshaft bearing cap setting ring pins from the camshaft housing sub-assembly.
      Fig 18: Identifying Camshaft Housing Sub-Assembly Bearing Cap Setting Ring Pins
      GTY316357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE STRAIGHT PIN 
    NOTE:

    It is not necessary to remove the straight pin unless it is being replaced.

    1. Remove the 2 straight pins from the camshaft housing sub-assembly.
      Fig 19: Identifying Camshaft Housing Sub-Assembly Straight Pins
      GTY322233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY  See step  27
  42. REMOVE VALVE LASH ADJUSTER ASSEMBLY  See step  28
  43. REMOVE VALVE STEM CAP  See step  29
  44. REMOVE CYLINDER HEAD SUB-ASSEMBLY  See step  30
  45. REMOVE CYLINDER HEAD GASKET  See step  31
  46. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    1. Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.
      Fig 20: Identifying Cylinder Block Water Jacket Spacer Component
      GTY195098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be sure to remove the cylinder block water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block sub-assembly is inverted.

  47. REMOVE OIL FILTER CAP ASSEMBLY  . Refer to REPLACEMENT [08/2013 - ] - Step 2
  48. REMOVE OIL PAN DRAIN PLUG 
    1. Remove the oil pan drain plug and gasket from the oil pan sub-assembly.
  49. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Remove the 11 bolts and 2 nuts.
      Fig 21: Identifying Oil Pan Sub-Assembly Bolts & Nuts
      GTY319181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Nut
    2. Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut off the applied sealer and remove the oil pan sub-assembly.
      Fig 22: View Of Inserting Blade Of SST Between No. 1 & No. 2 Oil Pans
      GTY192227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to damage the stiffening crankcase assembly contact surface of the oil pan sub-assembly.
      • Be careful not to damage the stiffening crankcase flange.
  50. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the 3 bolts, oil strainer sub-assembly and gasket.
      Fig 23: Oil Strainer & Bolts
      GTY184315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE NO. 1 OIL PAN BAFFLE PLATE 
    1. Remove the 5 bolts and No. 1 oil pan baffle plate.
      Fig 24: Oil Pan Baffle Plate Bolts
      GTY190555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSPECT CRANKSHAFT BACKLASH 
    1. Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.
      Fig 25: View Of Measuring Backlash Of Crankshaft And Balance Shaft
      GTY184440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard backlash

      0.05 to 0.20 mm (0.00197 to 0.00787 in.)

      Maximum backlash

      0.20 mm (0.00787 in.)

      If the backlash is more than the maximum, replace the engine balancer assembly.

  53. REMOVE ENGINE BALANCER ASSEMBLY 
    1. Remove the 7 bolts and engine balancer assembly.
      Fig 26: Locating Engine Balancer Bolts
      GTY195093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not disassemble the engine balancer assembly.

  54. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE  See step  14
  55. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE  See step  15
  56. REMOVE STIFFENING CRANKCASE ASSEMBLY 
    1. Remove the 7 bolts.
      Fig 27: Stiffening Crankcase Assembly Bolts
      GTY195095Courtesy 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 at the places shown in the illustration.
      Fig 28: Locating Stiffening Crankcase & Cylinder Block Prying Areas
      GTY303021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a LH Side
      *b RH Side
      NOTE:

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

      HINT: 

      Tape the screwdriver tip before use.

  57. REMOVE STUD BOLT 
    NOTE:

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

    1. Using an E5 and E8 "TORX" socket wrench, remove the 3 stud bolts from the stiffening crankcase assembly.
      Fig 29: Identifying Stiffening Crankcase Assembly Stud Bolts
      GTY322228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE RING PIN 
    NOTE:

    It is not necessary to remove the ring pin unless it is being replaced.

    1. Remove the 2 ring pins from the stiffening crankcase assembly.
      Fig 30: Identifying Stiffening Crankcase Assembly Ring Pins
      GTY316335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE REAR ENGINE OIL SEAL 
    1. Remove the rear engine oil seal from the cylinder block sub-assembly.
      Fig 31: View Of Rear Engine Oil Seal
      GTY195097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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