Engine Unit: Disassembly

1. Remove the oil filler cap and gasket.

1. Remove the radiator cap.

1. Remove the drain plug and gasket.

1. Remove the ventilation valve.
   Fig 1: Locating Ventilation Valve

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1. Remove the 4 bolts and 4 sensors.
   Fig 2: Locating Camshaft Position Sensor Bolts

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1. Remove the 4 bolts and 4 oil control valves.
   Fig 3: Identifying Oil Control Valves And Bolts

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1. Remove the bolt and sensor.
   Fig 4: Locating Sensor With Bolt

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1. Remove the oil check valve bolt, oil pipe union and oil pipe.
2. Remove the oil control valve filter LH and gaskets.
   Fig 5: Locating Oil Pipe Union And Oil Pipe

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1. Remove the oil check valve bolt, oil pipe union and oil pipe.
2. Remove the oil control valve filter RH and gaskets.
   Fig 6: Locating Oil Pipe Union And Oil Pipe

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1. Remove the water drain cocks from the cylinder block.
2. Remove the water drain cock plugs from the water drain cocks.
   Fig 7: Locating Cylinder Block Water Drain Cock Sub-Assembly

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1. Using SST, remove the oil filter cap.

   SST 09228-06501 

   HINT:

   Place a container for oil to be drained before removing the cap.

   Fig 8: Removing Oil Filter Cap

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2. Remove the oil filter element and O-ring from the oil filter cap.
   NOTE: Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.
   Fig 9: Identifying Oil Filter Element And O-Ring

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1. Using SST, loosen the crankshaft pulley bolt.

   SST 09213-70011 (09213-70020), 09330-00021 

   Fig 10: Loosening Crankshaft Pulley Bolt

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2. Using SST, remove the crankshaft pulley bolt and crankshaft pulley.

   SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) 

   Fig 11: Removing Crankshaft Pulley Bolt And Crankshaft Pulley

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1. Separate the 3 water by-pass hoses.
   Fig 12: Locating Water By-Pass Hoses

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2. Remove the 4 bolts, nut and water inlet.
   Fig 13: Locating Water Inlet, Bolts And Nut

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3. Remove the 2 O-rings.
   Fig 14: Locating O-Rings

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4. Remove the 3 water by-pass hoses.
   Fig 15: Locating Water By-Pass Hoses

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1. Remove the 3 nuts and water inlet with thermostat.
2. Remove the gasket from the water inlet.
   Fig 16: Locating Water Inlet With Thermostat Sub-Assembly

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1. Remove the 2 bolts, 4 nuts and water by-pass joint.
   Fig 17: Locating Water By-Pass Joint And Bolts

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2. Remove the 2 gaskets and O-ring.
   Fig 18: Locating Gaskets And O-Ring

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1. Remove the 14 bolts, head cover and gasket.
   Fig 19: Locating Cylinder Head Cover Bolts

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2. Remove the 3 gaskets.
   Fig 20: Locating Cylinder Head Cover And Gasket

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1. Remove the 12 bolts, head cover and gasket.
   NOTE: The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the head cover.
   Fig 21: Locating Head Cover And Bolts

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2. Remove the 3 gaskets.
   Fig 22: Locating Cylinder Head Cover And Gasket

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1. Pry up the claws of the ventilation baffle plate.
   NOTE: Do not deform the claws of the baffle plate more than necessary.
2. Remove the 6 gaskets from the cylinder head covers.
   NOTE:

   • As much as possible prevent the plug tube gaskets from being deformed. The removed gaskets will be used when reinstalling the gaskets.
   • Do not damage the connection of the cylinder head cover.
     Fig 23: Removing Spark Plug Tube Gasket

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1. Remove the 15 bolts and 2 nuts.
   Fig 24: Locating No. 2 Oil Pan Sub-Assembly

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2. Insert the blade of oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.
   NOTE: Be careful not to damage the contact surfaces of the oil pans.
   Fig 25: Removing No. 2 Oil Pan Sub-Assembly

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1. Remove the 16 bolts and 2 nuts.

   HINT:

   Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

   Fig 26: Locating Oil Pan Sub-Assembly Bolts

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2. Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.
   NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

   HINT:

   Tape the screwdriver tip before use.

   Fig 27: Locating Oil Pan And Cylinder Block

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3. Remove the 2 O-rings.
   Fig 28: Locating O-Rings

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1. Remove the 3 nuts, oil strainer and gasket.
   Fig 29: Locating Oil Strainer And Nuts

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2. Remove the 8 bolts and baffle plate.
   Fig 30: Locating Baffle Plate And Bolts

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1. Remove the 6 bolts.
   Fig 31: Locating Engine Rear Oil Seal Retainer And Bolt

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2. Using a screwdriver, pry out the oil seal retainer.
   NOTE: Be careful not to damage the engine rear oil seal retainer.

   HINT:

   Tape the screwdriver tip before use.

   Fig 32: Prying Oil Seal Retainer

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1. Place the oil seal retainer on wooden blocks.
   NOTE: Be careful not to damage the engine rear oil seal retainer.
2. Using a screwdriver and a hammer, tap out the oil seal.

   HINT:

   Tape the screwdriver tip before use.

   Fig 33: Tapping Oil Seal

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1. Remove the 16 bolts, water pump and gasket.
   Fig 34: Locating Water Pump And Bolts

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1. Remove the 16 bolts and 2 nuts as shown in the illustration.
   Fig 35: Locating Timing Chain Cover, Bolts And Nuts

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2. Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.
   NOTE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.

   HINT:

   Tape the screwdriver tip before use.

3. Remove the 4 bolts, chain cover plate and gasket.
   Fig 36: Removing Timing Chain Cover

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4. Remove the gasket.
   Fig 37: Locating Gasket

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1. Using a screwdriver, pry out the oil seal.

   HINT:

   Tape the screwdriver tip before use.

   Fig 38: Removing Timing Chain Case Oil Seal

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1. Temporarily tighten the pulley set bolt.
2. Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC / compression).
   Fig 39: Identifying Timing Mark On Crank Angle Sensor Plate

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3. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.

   If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.

   Fig 40: Identifying Timing Marks Of Camshaft Timing Gears

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1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
2. Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm (0.05 in.) into the stopper plate's hole.
   Fig 41: Removing No. 1 Chain Tensioner Assembly

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3. Remove the 2 bolts and chain tensioner.

1. Remove the chain tensioner slipper.
   Fig 42: Locating Chain Tensioner And Bolts

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1. Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket.
2. Remove the pulley set bolt.
   Fig 43: Identifying Chain Sub-Assembly

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3. Remove the chain from the crankshaft timing sprocket and place it on the crankshaft.
   Fig 44: Identifying Crankshaft Timing Sprocket And Place

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4. Turn the camshaft timing gear assembly on the RH bank clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the banks.
5. Remove the chain.
   Fig 45: Identifying Camshaft Timing Gear Assembly

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1. Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, sprocket and No. 1 idle gear shaft.
   Fig 46: Removing Idle Sprocket Assembly

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1. Remove the 2 bolts and vibration damper.
   Fig 47: Locating Vibration Damper And Bolts

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1. Remove the 2 vibration dampers.
   Fig 48: Locating Vibration Dampers

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1. Remove the crankshaft timing sprocket from the crankshaft.
2. Remove the 2 pulley set keys from the crankshaft.
   Fig 49: Identifying Crankshaft Timing Sprocket

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1. While raising the No. 2 chain tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix the No. 2 chain tensioner.
   Fig 50: Removing Camshaft Timing Gears And No. 2 Chain (For Bank 1)

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2. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.
   NOTE:

   • Be careful not to damage the cylinder head with the wrench.
   • Do not disassemble the camshaft timing gear assemblies.
3. Remove the No. 2 chain.
   Fig 51: Holding Hexagonal Portion Of Camshaft

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1. Remove the bolt and No. 2 chain tensioner.
   Fig 52: Locating No. 2 Chain Tensioner Bolts

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1. Check that the camshafts are positioned as shown in the illustration.
   Fig 53: Positioning Of Camshafts

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2. Uniformly loosen and remove the 9 bearing cap bolts in the sequence shown in the illustration.
   Fig 54: Locating Bearing Cap Bolts

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3. Uniformly loosen and remove the 14 bearing cap bolts in the sequence shown in the illustration.
   NOTE: Uniformly loosen the bolts while keeping the camshaft level.
4. Remove the 6 bearing caps.

Fig 55: Locating Bearing Cap Bolts

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1. Remove the camshaft.

1. Remove the No. 2 camshaft.

1. Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver.
   NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

   HINT:

   Tape the screwdriver tip before use.

   Fig 56: Locating Camshaft Housing Sub-Assembly

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1. While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix the No. 3 chain tensioner.
   Fig 57: Pushing No. 3 Chain Tensioner

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2. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.
   NOTE:

   • Be careful not to damage the cylinder head with the wrench.
   • Do not disassemble the camshaft timing gear assemblies.
   Fig 58: Holding Hexagonal Portion Of Camshaft

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3. Remove the No. 2 chain.

1. Remove the bolt and No. 3 chain tensioner.
   Fig 59: Locating No. 3 Chain Tensioner Bolt

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1. Check that the camshafts are positioned as shown in the illustration.
   Fig 60: Positioning Of Camshafts

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2. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
   Fig 61: Locating Bearing Cap Bolts In Sequence

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3. Uniformly loosen and remove the 13 bearing cap bolts in the sequence shown in the illustration.
   NOTE: Uniformly loosen the bolts while keeping the camshaft level.
4. Remove the 5 bearing caps.

1. Remove the No. 3 camshaft.

1. Remove the No. 4 camshaft.
   Fig 62: Locating Bearing Cap Bolts In Sequence

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1. Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.
   NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

   HINT:

   Tape the screwdriver tip before use.

1. Remove the 24 valve rocker arms.

   HINT:

   Arrange the removed parts in the correct order.

   Fig 63: Removing Camshaft Housing

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1. Remove the 24 valve lash adjusters from the cylinder head.

   HINT:

   Arrange the removed parts in the correct order.

1. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
   NOTE:

   • Be careful not to drop washers into the cylinder head.
   • Cylinder head warpage or cracking could result from removing bolts in an incorrect order.
     Fig 64: Locating Cylinder Head Bolts

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   Be sure to keep separate the removed parts for each installation position.

2. Remove the cylinder head and gasket.

1. Uniformly loosen and remove the bolts in the sequence shown in the illustration.
   Fig 65: Locating Cylinder Head Sub-Assembly Bolts Loosen Sequence

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2. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
   NOTE:

   • Be careful not to drop washers into the cylinder head.
   • Cylinder head warpage or cracking could result from removing bolts in an incorrect order.
     Fig 66: Locating Cylinder Head Bolts Loosening Sequence

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   Be sure to keep separate the removed parts for each installation position.

3. Remove the cylinder head and gasket.

1. Disconnect the knock sensor wire.
2. Disconnect the 2 knock sensor connectors.
   Fig 67: Identifying Knock Sensor

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3. Remove the 2 bolts and knock sensors.
   Fig 68: Locating Knock Sensor Connectors And Bolts

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1. Remove the 2 bolts and water outlet pipe.

1. Remove the valve stem caps from the cylinder heads.

   HINT:

   Arrange the removed parts in the correct order.

   Fig 69: Locating Water Outlet Pipe And Bolts

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1. Using SST, compress the compression spring and remove the valve spring retainer locks.

   SST 09202-70020 (09202-00010) 

2. Remove the retainer, compression spring and valve.

   HINT:

   Arrange the removed parts in the correct order.

   Fig 70: Removing Intake Valve

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1. Using SST, compress the compression spring and remove the valve spring retainer locks.

   SST 09202-70020 (09202-00010) 

2. Remove the retainer, compression spring and valve.

   HINT:

   Arrange the removed parts in the correct order.

   Fig 71: Removing Exhaust Valve

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1. Using needle-nose pliers, remove the oil seals.
   Fig 72: Locating Valve Stem Oil Seal

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1. Using compressed air and a magnetic finger, remove the valve spring seats by blowing air onto them.
   Fig 73: Removing Valve Spring Seat

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1. Using a 10 mm hexagon wrench, remove the 4 screw plugs and 4 gaskets.
   NOTE: If water leaks from the straight screw plug or the plug corrodes, replace it.
   Fig 74: Locating No. 1 Straight Screw Plug

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1. Using a 14 mm hexagon wrench, remove the screw plugs and gaskets.
   NOTE: If water leaks from the straight screw plug or the plug corrodes, replace it.

1. Remove the unions from the cylinder heads.

1. Heat the cylinder head to 80 to 100°C (176 to 212°F).
2. Place the cylinder head on wooden blocks.
   Fig 75: Locating No. 2 Straight Screw Plug

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3. Using SST and a hammer, tap out the guide bushes.

   SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) 

   Fig 76: Tapping Out Guide Bushes

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1. Heat the cylinder head to 80 to 100°C (176 to 212°F).
2. Place the cylinder head on wooden blocks.
3. Using SST and a hammer, tap out the guide bushes.

   SST 09201-10000 (09201 -01050), 09950-70010 (09951-07100) 

Fig 77: Tapping Guide Bushes

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1. Check that the matchmarks on the connecting rod and cap are aligned.

   HINT:

   The matchmarks on the connecting rods and caps are for ensuring the correct reassembly.

2. Remove the 2 connecting rod cap bolts.
3. Using the 2 removed connecting rod caps bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

   HINT:

   Keep the lower bearing inserted to the connecting rod cap.

4. Using a ridge reamer, remove all the carbon from the top of the cylinder.
5. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

   HINT:

   • Keep the bearing, connecting rod and cap together.
   • Arrange the piston and connecting rod assemblies in the correct order.
     Fig 78: Removing Carbon Top Of Cylinder With Ridge Reamer

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1. Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the several steps and in the sequence shown in the illustration.
   Fig 79: Locating Main Bearing Cap Bolts Loosening Sequence

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2. Uniformly loosen the 16 bearing cap bolts, in several steps, in the sequence shown in the illustration.
   Fig 80: Locating Bearing Cap Bolts Loosen Sequence

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3. Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and lower bearings.
   NOTE:

   • Push up on the cap little by little, from the right and left side alternately until the cap can be removed.
   • Be careful not to damage the joint surface of the cylinder block and the main bearing cap.
4. Remove the crankshaft.

HINT:

Arrange the removed parts in the correct order.

Fig 81: Removing Main Bearing Cap And Bolts

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1. Remove the upper bearings and upper thrust washers from the cylinder block.
   Fig 82: Locating Upper Bearings And Upper Thrust Washers

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1. Using a piston ring expander, remove the 2 compression rings.
2. Using a piston ring expander, remove the oil ring rail.
3. Remove the oil ring expander by hand.

   HINT:

   Arrange the removed parts in the correct order.

   Fig 83: Removing Piston Ring Set

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1. Disconnect the connecting rod from the piston.
   1. Using a screwdriver, pry off the snap rings from the piston.
      Fig 84: Removing Piston Sub-Assembly With Pin

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   2. Gradually heat the piston to approximately 80°C (176°F).
      Fig 85: Heating Piston

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   3. Using a brass bar and plastic hammer, lightly tap out the piston pin and remove the connecting rod.

      HINT:

      • The piston and pin are a matched set.
      • Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
        Fig 86: Removing Connecting Rod

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2. Using a gasket scraper, remove the carbon from the piston top.
   Fig 87: Removing Carbon Of Piston Top

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3. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
   Fig 88: Cleaning Piston Ring Grooves

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4. Using solvent and a brush, thoroughly clean the piston.
   NOTE: Do not use a wire brush.
   Fig 89: Cleaning Piston

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1. Using a 5 mm hexagon wrench, remove the bolts and oil nozzles.
2. Check the 3 oil nozzles for damage or clogging.
   Fig 90: Locating Oil Nozzles Bolts

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1. Using SST and press, press out the bush.

   SST 09222-30010 

   Fig 91: Pressing Out Bush

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