Disassembly [07/2019 - 10/2019]: Procedure
- REMOVE SPARK PLUG
Refer to PROCEDURE - Step 3
- REMOVE KNOCK CONTROL SENSOR
Refer to PROCEDURE - Step 2
- REMOVE ENGINE COOLANT TEMPERATURE SENSOR
Refer to PROCEDURE - Step 6
- REMOVE ENGINE OIL TEMPERATURE SENSOR (for TMMK Made)
Refer to PROCEDURE - Step 5
- REMOVE OIL PRESSURE SENSOR (OIL PRESSURE SENDER GAUGE ASSEMBLY) (for TMMK Made)
Refer to PROCEDURE - Step 5
- REMOVE STRAIGHT SCREW PLUG (for TMC Made)
- REMOVE OIL PRESSURE AND TEMPERATURE SENSOR (for TMC Made)
Refer to PROCEDURE - Step 5
- REMOVE OIL PRESSURE CONTROL VALVE ASSEMBLY
Refer to PROCEDURE - Step 2
- REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)
Refer to PROCEDURE - Step 2
- REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)
Refer to PROCEDURE - Step 3
- REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY
Refer to PROCEDURE - Step 2
- REMOVE O-RING
Refer to PROCEDURE - Step 3
- REMOVE CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY
Refer to PROCEDURE - Step 4
- REMOVE CAM TIMING CONTROL MOTOR O-RING
Refer to PROCEDURE - Step 5
- REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY
Refer to PROCEDURE - Step 3
- REMOVE ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING)
- REMOVE OIL FILLER CAP SUB-ASSEMBLY
- REMOVE OIL FILLER CAP GASKET
- REMOVE CRANKSHAFT POSITION SENSOR
Refer to PROCEDURE - Step 3
- REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)
Refer to PROCEDURE - Step 2
- REMOVE CRANKSHAFT PULLEY ASSEMBLY
- Using SST, hold the crankshaft pulley assembly and loosen the crankshaft pulley bolt. Further loosen the crankshaft pulley bolt until 2 or 3 threads remain screwed into the crankshaft.
*a Hold Turn - SST: 09213-54015
- SST: 09330-00021
- Using SST and the crankshaft pulley bolt, remove the crankshaft pulley assembly and crankshaft pulley bolt.
*1 Crankshaft Pulley Bolt *a Hold Turn - SST: 09950-50013
- 09951-05010
- 09952-05010
- 09953-05020
- 09954-05070
- 09957-04010
HINT:
Apply lubricant to the threads and end of SST.
- SST: 09950-50013
- Using SST, hold the crankshaft pulley assembly and loosen the crankshaft pulley bolt. Further loosen the crankshaft pulley bolt until 2 or 3 threads remain screwed into the crankshaft.
- REMOVE WATER OUTLET
- REMOVE WATER BY-PASS OUTLET SUB-ASSEMBLY
- REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
- Using an 8 mm socket wrench, remove the 4 bolts (A).
- Remove the 12 bolts (B) and cylinder head cover sub-assembly from the camshaft housing sub-assembly.
- Remove the 7 cylinder head cover gaskets from the cylinder head cover sub-assembly.
- Remove the camshaft bearing cap oil hole gasket from the No. 1 camshaft bearing cap.
- Using an 8 mm socket wrench, remove the 4 bolts (A).
- REMOVE SPARK PLUG TUBE GASKET
- REMOVE ENGINE MOUNTING BRACKET RH
- REMOVE STRAIGHT SCREW PLUG
- REMOVE NO. 2 TIMING CHAIN COVER ASSEMBLY
- Remove the 20 bolts.
- Remove the No. 2 timing chain cover assembly from the timing chain cover assembly by prying the No. 2 timing chain cover assembly with a screwdriver with its tip wrapped with protective tape.
*a Protective Tape - - NOTE:Be careful not to damage the contact surfaces of the No. 2 timing chain cover assembly and timing chain cover assembly.
- Remove the 20 bolts.
- REMOVE TIMING CHAIN COVER OIL SEAL
- SET NO. 1 CYLINDER TO TDC (COMPRESSION)
- Temporarily install the crankshaft pulley bolt.
*1 Crankshaft Timing Gear Key - - *a Approximately 7.4° *b Approximately 27.3° *c Approximately 24.3° *d Timing Mark - Rotate the crankshaft clockwise and align the crankshaft timing gear key as shown in the illustration.
- Check that the timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.
- Remove the crankshaft pulley bolt.
HINT:
As the No. 2 camshaft may rotate counterclockwise strongly when the crankshaft pulley bolt is removed, use a wrench to hold the hexagonal portion of the No. 2 camshaft.
- Temporarily install the crankshaft pulley bolt.
- REMOVE OIL PUMP DRIVE CHAIN SUB-ASSEMBLY
- Temporarily install the crankshaft pulley assembly with the crankshaft pulley bolt.
- Using SST, hold the crankshaft pulley assembly and remove the bolt.
*a Bolt - SST: 09213-54015
- SST: 09330-00021
- Remove SST, the crankshaft pulley bolt and crankshaft pulley assembly.
- Remove the chain tensioner plate and chain damper spring.
*1 Chain Tensioner Plate *2 Chain Damper Spring - Remove the oil pump drive sprocket, oil pump drive shaft sprocket and oil pump drive chain sub-assembly.
*1 Oil Pump Drive Chain Sub-assembly *2 Oil Pump Drive Sprocket *3 Oil Pump Drive Shaft Sprocket
- REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
- Hold the hexagonal portion of the No. 2 camshaft with a wrench and turn the camshaft timing exhaust gear assembly clockwise to loosen the chain sub-assembly between the camshaft timing exhaust gear assembly and camshaft timing gear assembly.
*a Loosen Turn - Using a wrench, hold the hexagonal portion of the camshaft.NOTE:
- Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube with the wrench.
- Do not disassemble the camshaft timing gear assembly.
*a Hold Turn - Using a 10 mm bi-hexagonal wrench, remove the bolt and camshaft timing gear assembly from the camshaft.
- Hold the hexagonal portion of the No. 2 camshaft with a wrench and turn the camshaft timing exhaust gear assembly clockwise to loosen the chain sub-assembly between the camshaft timing exhaust gear assembly and camshaft timing gear assembly.
- REMOVE CHAIN SUB-ASSEMBLY
- REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
- REMOVE CHAIN TENSIONER SLIPPER
- REMOVE NO. 1 CHAIN VIBRATION DAMPER
- REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
- REMOVE TIMING CHAIN COVER ASSEMBLY
- Remove the 19 bolts from the camshaft housing sub-assembly, cylinder head sub-assembly, cylinder block sub-assembly, stiffening crankcase assembly and oil pump assembly.
- Remove the timing chain cover assembly by prying between the cylinder head sub-assembly, camshaft housing sub-assembly, oil pump assembly, cylinder block sub-assembly and stiffening crankcase assembly with a screwdriver with its tip wrapped with protective tape.
*a Protective Tape - - NOTE:Be careful not to damage the contact surfaces of the cylinder head sub-assembly, camshaft housing sub-assembly, oil pump assembly, cylinder block sub-assembly, stiffening crankcase assembly and timing chain cover assembly.
- Remove the 19 bolts from the camshaft housing sub-assembly, cylinder head sub-assembly, cylinder block sub-assembly, stiffening crankcase assembly and oil pump assembly.
- REMOVE OIL NOZZLE VALVE SUB-ASSEMBLY
- REMOVE CRANKSHAFT TIMING GEAR KEY
- REMOVE FUEL PUMP LIFTER GUIDE
- REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY
- Uniformly loosen and remove the 18 bolts in the order shown in the illustration.
- Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver.NOTE:
Be careful not to damage the contact surfaces of the cylinder head sub-assembly and camshaft housing sub-assembly.
HINT:
Tape the screwdriver tip before use.
- REMOVE CAMSHAFT BEARING CAP
- Remove the 8 bolts in the order shown in the illustration.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
*1 No. 1 Camshaft Bearing Cap *2 No. 2 Camshaft Bearing Cap *3 No. 3 Camshaft Bearing Cap *4 No. 4 Camshaft Bearing Cap - Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 2 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap.
HINT:
Arrange the removed parts in such a way that they can be reinstalled to their original locations.
- Remove the 8 bolts in the order shown in the illustration.
- REMOVE CAMSHAFT
- REMOVE NO. 2 CAMSHAFT
- REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
- REMOVE VALVE LASH ADJUSTER ASSEMBLY
- REMOVE VALVE STEM CAP
- REMOVE WATER SEAL PLATE
- REMOVE CYLINDER HEAD SUB-ASSEMBLY
- Using a 12 mm socket wrench, uniformly loosen the 10 cylinder head set bolts in the order shown in the illustration. Remove the 10 cylinder head set bolts and 10 plate washers.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Front of Engine NOTE:- Be careful not to drop the plate washers into the cylinder head sub-assembly.
- Warpage or cracking of the cylinder head sub-assembly may result from removing the cylinder head set bolts in the incorrect order.
HINT:
Arrange the removed parts in such a way that they can be reinstalled to their original locations.
- Remove the cylinder head sub-assembly from the cylinder block sub-assembly.
- Using a 12 mm socket wrench, uniformly loosen the 10 cylinder head set bolts in the order shown in the illustration. Remove the 10 cylinder head set bolts and 10 plate washers.
- REMOVE CYLINDER HEAD GASKET
Refer to PROCEDURE - Step 65
- REMOVE CYLINDER BLOCK WATER JACKET SPACER
- REMOVE OIL FILTER SUB-ASSEMBLY
Refer to PROCEDURE - Step 3
- REMOVE OIL PAN DRAIN PLUG
- Remove the oil pan drain plug and gasket from the No. 2 oil pan sub-assembly.
- REMOVE OIL FILTER UNION
- Using a 12 mm hexagon socket wrench, remove the oil filter union from the stiffening crankcase assembly.
- REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
- Remove the 11 bolts and 2 nuts.
*a Nut - Insert the blade of an oil pan seal cutter between the No. 2 oil pan sub-assembly and stiffening crankcase assembly, 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 stiffening crankcase assembly and No. 2 oil pan sub-assembly.
- Be careful not to damage the No. 2 oil pan sub-assembly flange.
- Remove the 11 bolts and 2 nuts.
- REMOVE OIL STRAINER SUB-ASSEMBLY
- REMOVE ENGINE OIL LEVEL SENSOR
Refer to PROCEDURE - Step 7
- REMOVE OIL PUMP BRACKET
- INSPECT CRANKSHAFT BACKLASH
- REMOVE ENGINE BALANCER ASSEMBLY
- REMOVE OIL PUMP ASSEMBLY
Refer to PROCEDURE - Step 7
- REMOVE STIFFENING CRANKCASE ASSEMBLY
- Remove the 7 bolts.
- 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.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.
- Remove the 7 bolts.
- REMOVE STRAIGHT SCREW PLUG
- REMOVE WIRE HARNESS CLAMP BRACKET
- Stiffening crankcase assembly side:
- Cylinder block sub-assembly side:
- Camshaft housing sub-assembly side:
- REMOVE STUD BOLT NOTE:
If a stud bolt is deformed or its threads are damaged, replace it.
- REMOVE RING PIN NOTE:
It is not necessary to remove the ring pins unless they are being replaced.
- REMOVE STRAIGHT PIN NOTE:
It is not necessary to remove the straight pins unless they are being replaced.
- REMOVE REAR ENGINE OIL SEAL