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Disassembly [10/2018 - ]: Procedure

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  1. REMOVE SPARK PLUG 

    Refer to PROCEDURE - Step 3

  2. REMOVE KNOCK SENSOR 

    Refer to PROCEDURE - Step 2

  3. REMOVE OIL PRESSURE AND TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 2

  4. REMOVE OIL PRESSURE CONTROL VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 2

  5. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side) 

    Refer to PROCEDURE - Step 2

  6. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side) 

    Refer to PROCEDURE - Step 3

  7. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY 

    Refer to PROCEDURE - Step 1

  8. REMOVE CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY 

    Refer to PROCEDURE - Step 2 [10/2018 - 07/2022] , or refer to PROCEDURE - Step 2 [07/2022 - ]

  9. REMOVE CAM TIMING CONTROL MOTOR O-RING 

    Refer to PROCEDURE - Step 3 [10/2018 - 07/2022] , or refer to PROCEDURE - Step 3 [07/2022 - ]

  10. REMOVE OIL FILLER CAP ASSEMBLY 
    1. Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.
      GTY811821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE OIL FILLER CAP GASKET 
    1. Remove the oil filler cap gasket from the oil filler cap sub-assembly.
      GTY652152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 2

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

    Refer to PROCEDURE - Step 2

  14. REMOVE CRANKSHAFT PULLEY ASSEMBLY 
    1. Using SST, hold the crankshaft pulley assembly and loosen the crankshaft pulley set bolt. Further loosen the crankshaft pulley set bolt until 2 or 3 threads remain screwed into the crankshaft.
      GTY798300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
      • SST: 09213-54015 
      • SST: 09330-00021 
    2. Using SST and the crankshaft pulley set bolt, remove the crankshaft pulley assembly and crankshaft pulley set bolt.
      GTY792959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Pulley Set Bolt
      *a Hold
      *b Turn
      • SST: 09950-50013 
        1. 09951-05010
        2. 09952-05010
        3. 09953-05020
        4. 09954-05070
        5. 09957-04010

      HINT: 

      Apply lubricant to the threads and end of SST.

  15. REMOVE WATER OUTLET 
    1. Remove the 2 bolts, water outlet and water outlet gasket from the cylinder head sub-assembly.
      GTY820682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE OUTLET WATER BY-PASS SUB-ASSEMBLY 
    1. Using an 8 mm socket wrench, remove the 3 bolts, outlet water by-pass sub-assembly and outlet water pipe gasket from the cylinder head sub-assembly.
      GTY820303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Using an 8 mm socket wrench, remove the 16 bolts and cylinder head cover sub-assembly from the camshaft housing sub-assembly.
      GTY835313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 7 cylinder head cover gaskets from the cylinder head cover sub-assembly.
      GTY811823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the camshaft bearing cap oil hole gasket from the No. 1 camshaft bearing cap.
      GTY811822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE SPARK PLUG TUBE GASKET 
    1. Using a screwdriver, pry out the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.
      GTY824527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

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

      HINT: 

      Tape the screwdriver tip before use.

  19. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 3 bolts and engine mounting bracket RH from the No. 2 timing chain cover assembly.
      GTY811824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE STRAIGHT SCREW PLUG 
    1. Using a 10 mm hexagon wrench, remove the straight screw plug from the No. 2 timing chain cover assembly.
      GTY809907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE NO. 2 TIMING CHAIN COVER ASSEMBLY 
    1. Remove the 20 bolts.
      GTY809908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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.
      GTY780638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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.

  22. REMOVE TIMING CHAIN COVER OIL SEAL 
    1. Using a screwdriver and wooden block, pry out the timing chain cover oil seal.
      NOTE:

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

      GTY771903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      *b Wooden Block

      HINT: 

      Tape the screwdriver tip before use.

  23. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 
    1. Temporarily install the crankshaft pulley bolt.
      GTY775709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Timing Gear Key - -
      *a Approximately 4.63° *b Approximately 33.07°
      *c Approximately 2.73° *d Timing Mark
    2. Rotate the crankshaft clockwise and align the crankshaft timing gear key as shown in the illustration.
    3. Check that the timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.
    4. Remove the crankshaft pulley bolt.

      HINT: 

      As the exhaust camshaft sub-assembly may rotate counterclockwise strongly when the crankshaft pulley bolt is removed, use a wrench to hold the hexagonal portion of the exhaust camshaft sub-assembly.

  24. REMOVE OIL PUMP DRIVE CHAIN SUB-ASSEMBLY 
    1. Temporarily install the crankshaft pulley assembly with the crankshaft pulley bolt.
    2. While holding the crankshaft pulley assembly with SST, remove the bolt.
      GTY802020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt
      • SST: 09213-54015 
      • SST: 09330-00021 
    3. Remove SST, the crankshaft pulley bolt and crankshaft pulley assembly.
    4. Remove the chain tensioner plate and chain damper spring.
      GTY799066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Chain Tensioner Plate
      *2 Chain Damper Spring
    5. Remove the oil pump drive sprocket, oil pump drive shaft sprocket and oil pump drive chain sub-assembly.
      GTY750003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Pump Drive Chain Sub-assembly
      *2 Oil Pump Drive Sprocket
      *3 Oil Pump Drive Shaft Sprocket
  25. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Hold the hexagonal portion of the exhaust camshaft sub-assembly with a wrench and turn the camshaft timing gear assembly clockwise to loosen the chain sub-assembly between the camshaft timing exhaust gear assembly and camshaft timing gear assembly.
      GTY911411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Loosen
      Turn
    2. Using a wrench, hold the hexagonal portion of the intake camshaft sub-assembly.
      GTY905706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      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.
    3. Using a 10 mm bi-hexagonal wrench, remove the bolt and camshaft timing gear assembly from the intake camshaft sub-assembly.
  26. REMOVE CHAIN SUB-ASSEMBLY 
    1. Remove the crankshaft timing sprocket and chain sub-assembly.
      GTY964561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Remove the bolt.
      GTY945605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut and No. 1 chain tensioner assembly from the timing chain cover assembly.
      NOTE:

      Make sure that the plunger, check ball assembly and spring do not come out.

    3. Use tape to hold the plunger inside the No. 1 chain tensioner assembly.
      GTY824624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tape
      NOTE:
      • Make sure that the plunger, check ball assembly and spring do not come out.
      • If the No. 1 chain tensioner assembly comes apart, reinstall the parts as shown in the illustration.
        GTY779353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Plunger *b Check Ball Assembly
        *c Spring *d No. 1 Chain Tensioner Assembly Body
  28. REMOVE CHAIN TENSIONER SLIPPER 
    1. Remove the bolt and chain tensioner slipper from the timing chain cover assembly.
      GTY926155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE NO. 1 CHAIN VIBRATION DAMPER 
    1. Remove the 2 bolts and No. 1 chain vibration damper from the timing chain cover assembly.
      GTY802431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Using a wrench, hold the hexagonal portion of the No. 2 camshaft.
      GTY926153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly or spark plug tube with the wrench.

    2. Using a 5 mm hexagon socket wrench, remove the 3 bolts.
    3. Remove the camshaft timing exhaust gear assembly and camshaft timing oil control valve assembly (exhaust camshaft timing gear bolt assembly) from the exhaust camshaft sub-assembly.
      GTY852062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 Camshaft Timing Oil Control Valve Assembly (Exhaust Camshaft Timing Gear Bolt Assembly)
  31. REMOVE TIMING CHAIN COVER ASSEMBLY 
    1. Remove the 20 bolts and timing chain cover assembly from the camshaft housing sub-assembly, cylinder head sub-assembly, cylinder block sub-assembly, stiffening crankcase assembly and oil pump assembly.
      GTY833002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the timing chain cover assembly by prying between the cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly with a screwdriver with its tip wrapped with protective tape.
      GTY774988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 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 assembly.

  32. REMOVE OIL NOZZLE VALVE SUB-ASSEMBLY 
    1. Remove the oil nozzle valve sub-assembly from the cylinder block sub-assembly.
      GTY809232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE CRANKSHAFT TIMING GEAR KEY 
    1. Using a screwdriver, remove the 2 crankshaft timing gear keys from the crankshaft.
      GTY760187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      HINT: 

      Tape the screwdriver tip before use.

  34. REMOVE FUEL PUMP LIFTER GUIDE 
    1. Using an 8 mm socket wrench, remove the 2 bolts and fuel pump lifter guide from the No. 4 camshaft bearing cap.
      GTY833240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY 
    1. Uniformly loosen and remove the 17 bolts in the order shown in the illustration.
      Fig 1: Camshaft Housing Sub-Assembly Bolts Loosening Sequence
      GTY817023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver.
      GTY756761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.

  36. REMOVE CAMSHAFT BEARING CAP 
    1. Remove the 9 bolts in the order shown in the illustration.
      Fig 2: Camshaft Bearing Cap Loosening Sequence
      GTY800501Courtesy 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
    2. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 2 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap from the camshaft housing sub-assembly.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  37. REMOVE INTAKE CAMSHAFT SUB-ASSEMBLY 
    1. Remove the intake camshaft sub-assembly from the camshaft housing sub-assembly.
      GTY801336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE EXHAUST CAMSHAFT SUB-ASSEMBLY 
    1. Remove the exhaust camshaft sub-assembly from the camshaft housing sub-assembly.
      GTY801330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Remove the 16 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

      GTY757628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE VALVE LASH ADJUSTER ASSEMBLY 
    1. Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

      GTY757627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE VALVE STEM CAP 
    1. Remove the 16 valve stem caps from the cylinder head sub-assembly.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

      GTY757626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE WATER SEAL PLATE 
    1. Using an 8 mm socket wrench, remove the 2 bolts, water seal plate and water seal plate gasket from the cylinder head sub-assembly.
      GTY820702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE CYLINDER HEAD SUB-ASSEMBLY 
    1. 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.
      Fig 3: Cylinder Head Sub-Assembly Loosening Sequence
      GTY760825Courtesy 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.

    2. Remove the cylinder head sub-assembly from the cylinder block sub-assembly.
  44. REMOVE CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 62 [10/2018 - 07/2022] , or refer to PROCEDURE - Step 62 [07/2022 - ]

  45. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    1. Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.
      GTY809301Courtesy 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.

  46. REMOVE OIL FILTER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  47. REMOVE OIL FILTER UNION 
    GTY820701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a 12 mm hexagon socket wrench, remove the oil filter union from the stiffening crankcase assembly.
  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 12 bolts and 2 nuts.
      GTY818876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
    2. Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut through the applied sealer and remove the oil pan sub-assembly.
      GTY192227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to damage the contact surfaces of the stiffening crankcase assembly and oil pan sub-assembly.
      • Be careful not to damage the oil pan sub-assembly flange.
  50. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Using an 8 mm socket wrench, remove the bolt, oil strainer sub-assembly and oil strainer gasket from the stiffening crankcase assembly.
      GTY820698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE ENGINE OIL LEVEL SENSOR 

    Refer to PROCEDURE - Step 4

  52. REMOVE ENGINE BALANCER ASSEMBLY 
    1. Remove the 6 bolts and engine balancer assembly from the stiffening crankcase assembly
      NOTE:

      Do not disassemble the engine balancer assembly

      GTY820697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE OIL PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 6 [10/2018 - 07/2022] , or refer to PROCEDURE - Step 6 [07/2022 - ]

  54. REMOVE STIFFENING CRANKCASE ASSEMBLY 
    1. Remove the 7 bolts.
      GTY820710Courtesy 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.
      GTY809233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.

  55. REMOVE STRAIGHT SCREW PLUG 
    1. Using a 10 mm hexagon socket wrench, remove the straight screw plug and gasket from the stiffening crankcase assembly.
      GTY820693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. REMOVE STUD BOLT 
    NOTE:

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

  57. REMOVE RING PIN 
    NOTE:

    It is not necessary to remove the ring pins unless they are being replaced.

  58. REMOVE STRAIGHT PIN 
    NOTE:

    It is not necessary to remove the straight pins unless they are being replaced.

  59. REMOVE REAR ENGINE OIL SEAL 
    1. Remove the rear engine oil seal from the cylinder block sub-assembly.
      GTY809921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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