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Disassembly [03/2024 - ]: Procedure

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  1. REMOVE SPARK PLUG 
    Refer to PROCEDURE - Step 3
  2. REMOVE KNOCK CONTROL SENSOR 
    Refer to PROCEDURE - Step 2
  3. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    Refer to PROCEDURE - Step 3
  4. REMOVE STRAIGHT SCREW PLUG 
    1. GTY997973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE OIL PRESSURE AND TEMPERATURE SENSOR 
    Refer to PROCEDURE - Step 2
  6. REMOVE OIL PRESSURE CONTROL VALVE ASSEMBLY 
    Refer to PROCEDURE - Step 2
  7. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY 
    Refer to PROCEDURE - Step 3
  8. REMOVE CAM TIMING OIL CONTROL SOLENOID O-RING 
    Refer to PROCEDURE - Step 4
  9. REMOVE CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY 
    Refer to PROCEDURE - Step 6
  10. REMOVE CAM TIMING CONTROL MOTOR O-RING 

    Refer to PROCEDURE - Step 7

  11. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 8
  12. REMOVE ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING) 
    1. GTY997975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
    1. GTY997980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE OIL FILLER CAP GASKET 
    1. GTY997263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE CRANKSHAFT POSITION SENSOR 
    Refer to PROCEDURE - Step 5
  16. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 

    Refer to PROCEDURE - Step 2

  17. DISCONNECT NO. 1 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 7

  18. DISCONNECT NO. 2 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 8

  19. REMOVE OIL COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 9

  20. REMOVE OIL COOLER GASKET 

    Refer to PROCEDURE - Step 10

  21. REMOVE OIL CONTROL VALVE FILTER (w/ Filter) 

    Refer to PROCEDURE - Step 11

  22. REMOVE NO. 1 WATER BY-PASS HOSE 
    1. GTY1001200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE NO. 2 WATER BY-PASS HOSE 
    1. GTY1001139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE CRANKSHAFT PULLEY ASSEMBLY 
    1. GTY1075254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Pulley Bolt - -
      *a Hold - -
      Turn - -
      1. Using SST, hold the crankshaft pulley assembly and loosen the crankshaft pulley bolt.
        • SST: 09213-54015 
        • SST: 09330-00021 
      2. Further loosen the crankshaft pulley bolt until 2 or 3 threads remain screwed into the crankshaft.
      3. Apply lubricant to the threads and end of SST.
        • SST: 09950-50013 
          1. 09951-05010
          2. 09952-05010
          3. 09953-05020
          4. 09954-05070
          5. 09957-04010
      4. Using SST and the crankshaft pulley bolt, remove the crankshaft pulley assembly and crankshaft pulley bolt.
  25. REMOVE WATER OUTLET 
    1. GTY1075775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the 3 bolts and water outlet from the cylinder head sub-assembly.
  26. REMOVE WATER OUTLET GASKET 
    1. GTY998867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE WATER BY-PASS OUTLET 
    1. GTY1074981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the 3 bolts and water by-pass outlet from the cylinder head sub-assembly.
  28. REMOVE WATER OUTLET PIPE GASKET 
    1. GTY999159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side) 
    Refer to PROCEDURE - Step 2
  30. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side) 
    Refer to PROCEDURE - Step 3
  31. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. GTY1075618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the 4 bolts (A).
      2. Remove the 12 bolts (B) and cylinder head cover sub-assembly from the camshaft housing sub-assembly.
      3. Remove the 7 gaskets from the cylinder head cover sub-assembly.
      4. Remove the gasket from the No. 1 camshaft bearing cap.
  32. REMOVE SPARK PLUG TUBE GASKET 
    1. GTY1075068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver with its tip wrapped with protective tape, pry out the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.
        NOTE:

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

  33. REMOVE ENGINE MOUNTING BRACKET RH 
    NOTE:

    When removing and installing or replacing the engine mounting bracket RH, remove the No. 2 timing chain cover assembly, reapply seal packing, then reassemble.
    1. GTY997091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE STRAIGHT SCREW PLUG 
    1. GTY1074834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 10 mm hexagon socket wrench, remove the straight screw plug from the No. 2 timing chain cover assembly.
  35. REMOVE NO. 2 TIMING CHAIN COVER ASSEMBLY 
    1. GTY998062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. GTY1076063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. 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.
        NOTE:

        Be careful not to damage the contact surfaces of the No. 2 timing chain cover assembly and timing chain cover assembly.

  36. REMOVE TIMING CHAIN COVER OIL SEAL 
    1. GTY1074933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver with its tip wrapped with protective tape 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.

  37. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 
    1. GTY1075249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the crankshaft pulley bolt.
    2. GTY1074879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Timing Gear Key - -
      *a Approximately 7.4° *b Approximately 27.3°
      *c Approximately 24.3° *d Timing Mark
      1. Rotate the crankshaft clockwise and align the crankshaft timing gear key as shown in the illustration.
      2. If the timing marks are not aligned, rotate the crankshaft clockwise and realign the timing marks.
    3. GTY1075404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. While holding the hexagonal portion of the No. 2 camshaft, remove the crankshaft pulley bolt.
        NOTE:

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

  38. REMOVE OIL PUMP DRIVE CHAIN SUB-ASSEMBLY 
    1. GTY1075811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Chain Tensioner Plate *2 Chain Damper Spring
      *3 Oil Pump Drive Chain Sub-assembly *4 Oil Pump Drive Sprocket
      *5 Oil Pump Drive Shaft Sprocket - -
      *a Bolt - -
      1. Temporarily install the crankshaft pulley assembly with the crankshaft pulley bolt.
      2. Using SST, hold the crankshaft pulley assembly and remove the 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.
      5. Remove the oil pump drive sprocket, oil pump drive shaft sprocket and oil pump drive chain sub-assembly.
  39. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 
    1. GTY1075910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Loosen *b Hold
      Turn - -
      1. 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.
      2. 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.
      3. Using a 10 mm bi-hexagon socket wrench, remove the bolt and camshaft timing gear assembly from the camshaft.
  40. REMOVE CHAIN SUB-ASSEMBLY 
    1. GTY998067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. GTY1074987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the bolt.
      2. Remove the nut and No. 1 chain tensioner assembly.
        NOTE:

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

    2. GTY1075122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tape *b Plunger
      *c Check Ball Assembly *d Spring
      *e No. 1 Chain Tensioner Assembly Body *f Oil Hole
      1. Use tape to hold the plunger inside the No. 1 chain tensioner assembly.
        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.
  42. REMOVE CHAIN TENSIONER SLIPPER 
    1. GTY998080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE NO. 1 CHAIN VIBRATION DAMPER 
    1. GTY997094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. GTY1131670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Type A *B Type B
      *1 Camshaft Timing Exhaust Gear Assembly *2 Camshaft Timing Valve Assembly
      *a Hold - -
      1. Using a wrench, hold the hexagonal portion of the No. 2 camshaft.
        NOTE:

        Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly and 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 valve assembly.
  45. REMOVE TIMING CHAIN COVER ASSEMBLY 
    1. GTY998084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      GTY1074908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the timing chain cover assembly by prying between the cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly, oil pump assembly and stiffening crankcase assembly with a screwdriver with its tip wrapped with 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, oil pump assembly, stiffening crankcase assembly and timing chain cover assembly.

  46. REMOVE OIL NOZZLE VALVE SUB-ASSEMBLY 
    1. GTY998085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE CRANKSHAFT TIMING GEAR KEY 
    NOTE:

    Be careful not to damage the crankshaft.
    1. GTY1075514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver with its tip wrapped with protective tape, remove the 2 crankshaft timing gear keys.
  48. REMOVE FUEL PUMP LIFTER GUIDE 
    1. GTY1075825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the 2 bolts and fuel pump lifter guide from the No. 4 camshaft bearing cap.
  49. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY 
    1. GTY1076016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Uniformly loosen the 18 bolts in the order shown in the illustration.
      2. Remove the 18 bolts.
      3. Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver with its tip wrapped with protective tape.
        NOTE:

        Be careful not to damage the contact surfaces of the cylinder head sub-assembly and camshaft housing sub-assembly.

  50. REMOVE CAMSHAFT BEARING CAP 
    1. GTY1075943Courtesy 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
      1. Remove the 8 bolts in the order shown in the illustration.
      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.
  51. REMOVE CAMSHAFT 
    1. GTY998087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE NO. 2 CAMSHAFT 
    1. GTY998019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. GTY1075531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Camshaft Housing Sub-assembly Side - -
      1. Using an 8 mm socket wrench, remove the bolt and wire harness clamp bracket.
  54. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. GTY997271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE VALVE LASH ADJUSTER ASSEMBLY 
    1. GTY998017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. REMOVE VALVE STEM CAP 
    1. GTY998018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. GTY1076504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the 2 bolts and water by-pass pipe sub-assembly from the cylinder head sub-assembly.
  58. REMOVE WATER BY-PASS PIPE GASKET 
    1. GTY1001506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE CYLINDER HEAD SUB-ASSEMBLY 
    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.
    1. GTY1076022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Front of Engine - -
      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, 10 plate washers and cylinder head sub-assembly.
  60. REMOVE CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 89

  61. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    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.
    1. GTY998020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE OIL FILTER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  63. REMOVE OIL PAN DRAIN PLUG 
    1. GTY998027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE OIL FILTER UNION 
    1. GTY1074974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 12 mm straight hexagon wrench, remove the oil filter union from the stiffening crankcase assembly.
  65. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY 
    1. GTY1075680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut - -
      1. Remove the 11 bolts and 2 nuts.
      2. 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.
      3. Clean and inspect the bolts, nuts and stud bolts.
  66. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. GTY1075065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the bolt, oil strainer sub-assembly and gasket.
  67. REMOVE ENGINE OIL LEVEL SENSOR 
    Refer to PROCEDURE - Step 4
  68. REMOVE OIL PUMP BRACKET 
    1. GTY998035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. INSPECT CRANKSHAFT BACKLASH 
    1. GTY1075169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.

        Standard Backlash

        0.05 to 0.20 mm (0.00197 to 0.00787 in.)

        Maximum Backlash

        0.20 mm (0.00787 in.)

      2. If the backlash is more than the maximum, replace the engine balancer assembly.
  70. REMOVE ENGINE BALANCER ASSEMBLY 
    NOTE:

    Do not disassemble the engine balancer assembly.
    1. GTY998033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE OIL PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 7

  72. REMOVE STIFFENING CRANKCASE ASSEMBLY 
    1. GTY1075758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the 7 bolts.
      2. Using a screwdriver with its tip wrapped with protective tape, 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.

  73. REMOVE STRAIGHT SCREW PLUG 
    1. GTY1075268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 10 mm hexagon socket wrench, remove the 3 straight screw plugs and 3 gaskets from the stiffening crankcase assembly.
  74. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. GTY1076415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the bolt and wire harness clamp bracket.
    2. GTY1254251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE REAR ENGINE OIL SEAL 
    1. GTY998037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE STUD BOLT 
    NOTE:

    If a stud bolt is deformed or its threads are damaged, replace it.
    1. GTY1075437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the stiffening crankcase assembly.
    2. GTY1074880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an E6 "TORX" socket wrench, remove the stud bolt from the timing chain cover assembly.
    3. GTY1078206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. w/ Stud Bolt:

        1. Using an E8 "TORX" socket wrench, remove the stud bolt from the cylinder head sub-assembly.

  77. REMOVE RING PIN 
    NOTE:

    It is not necessary to remove the ring pins unless they are being replaced.
    1. GTY998756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Camshaft Housing Sub-assembly Upper Side - -
    2. GTY999604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Stiffening Crankcase Assembly Side - -
    3. GTY999336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Timing Chain Cover Assembly Side - -
  78. REMOVE STRAIGHT PIN 
    NOTE:

    It is not necessary to remove the straight pins unless they are being replaced.
    1. GTY998890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A No. 2 Timing Chain Cover Assembly Side - -
    2. GTY999539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Timing Chain Cover Assembly Side - -
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