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Disassembly [10/2015 - ]: Procedure

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  1. REMOVE SPARK PLUG 

    Refer to PROCEDURE - Step 3

  2. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side) 

    Refer to PROCEDURE - Step 3

  3. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side) 

    Refer to PROCEDURE - Step 2

  4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 2

  5. REMOVE KNOCK SENSOR 

    Refer to PROCEDURE - Step 2

  6. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY 

    Refer to PROCEDURE - Step 2

  7. REMOVE CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 2

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

    Refer to PROCEDURE - Step 2

  9. REMOVE NO. 1 VENTILATION CASE 
    1. Remove the 6 bolts and 2 nuts.
      GTY638311Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Using a screwdriver, remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block sub-assembly.
      GTY642222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to damage the contact surfaces of the cylinder block sub-assembly.
      • Do not reuse the No. 1 ventilation case.

      HINT: 

      Tape the screwdriver tip before use.

  10. REMOVE CRANKSHAFT PULLEY ASSEMBLY 
    1. Using SST, hold the crankshaft pulley assembly and loosen the crankshaft pulley set bolt until 2 or 3 threads remain screwed into the crankshaft.
      • SST: 09213-54015 
      • SST: 09330-00021 
      GTY621342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn

      HINT: 

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)

    2. Using SST and the crankshaft pulley set bolt, remove the crankshaft pulley assembly from the crankshaft.
      • SST: 09950-50013 
        1. 09951-05010
        2. 09952-05010
        3. 09953-05020
        4. 09954-05011
        5. 09957-04010
      GTY650314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Pulley Set Bolt
      *a Hold
      *b Turn

      HINT: 

      Apply lubricant to the threads and end of SST.

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 19 bolts and cylinder head cover sub-assembly from the camshaft housing sub-assembly.
      GTY678890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the camshaft bearing cap oil hole gasket from the No. 1 camshaft bearing cap.
      GTY624341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Bearing Cap Oil Hole Gasket
      *2 Gasket
    3. Remove the gasket from the No. 2 camshaft bearing cap.
  12. REMOVE CYLINDER HEAD COVER GASKET 
    1. Remove the cylinder head cover gasket and No. 2 cylinder head cover gasket from the cylinder head cover sub-assembly.
      GTY664960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cylinder Head Cover Gasket
      *2 No. 2 Cylinder Head Cover Gasket
  13. REMOVE SPARK PLUG TUBE GASKET 
    1. Using a screwdriver, remove the spark plug tube gasket from the cylinder head cover sub-assembly.
      GTY632801Courtesy 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.

  14. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY 

    Refer to PROCEDURE - Step 3

  15. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 5

  16. REMOVE WATER OUTLET SUB-ASSEMBLY 
    1. Slide the clamp and disconnect the No. 6 water by-pass hose from the water outlet sub-assembly.
      GTY679101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts, nut and water outlet sub-assembly from the timing chain cover assembly.
    3. Remove the O-ring from the timing chain cover assembly.
  17. REMOVE TIMING CHAIN COVER ASSEMBLY 

    Refer to PROCEDURE - Step 24

  18. REMOVE TIMING CHAIN COVER OIL SEAL 

    Refer to PROCEDURE - Step 25

  19. REMOVE TIMING CHAIN COVER PLATE 
    1. Remove the 4 bolts, timing chain cover plate and gasket from the timing chain cover assembly.
      GTY642458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Temporarily install the crankshaft pulley set bolt.
    2. Rotate the crankshaft clockwise and align the timing marks (groove) on the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft pulley set key of the crankshaft timing sprocket as shown in the illustration.
      GTY836537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Pulley Set Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark (Groove) - -

      HINT: 

      If the timing marks are not aligned, rotate the crankshaft clockwise again and align the timing marks.

    3. Remove the crankshaft pulley set bolt.
  21. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Allow the plunger to extend slightly, and then rotate the stopper plate counterclockwise to release the lock. Once the lock is released, push the plunger into the No. 1 chain tensioner assembly.
      GTY625031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Stopper Plate
      *b Plunger
    2. Rotate the stopper plate clockwise to set the lock, and then insert a pin into the stopper plate hole.
      GTY631643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
    3. Remove the nut, bolt, No. 1 chain tensioner assembly and gasket from the cylinder block sub-assembly.
      GTY642466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE TIMING CHAIN GUIDE 
    1. Remove the bolt and timing chain guide from the No. 1 camshaft bearing cap.
      GTY518504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE CHAIN TENSIONER SLIPPER 
    1. Remove the bolt and chain tensioner slipper from the cylinder head sub-assembly.
      GTY679102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE CHAIN SUB-ASSEMBLY 
    1. Remove the chain sub-assembly.
  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER 
    1. Remove the 2 bolts and No. 1 chain vibration damper from the cylinder head sub-assembly and cylinder block sub-assembly.
      GTY642463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE CRANKSHAFT TIMING SPROCKET 
    1. Remove the crankshaft timing sprocket from the crankshaft.
      GTY642467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Using a wrench to hold the hexagonal portion of the camshaft, remove the camshaft timing gear bolt and camshaft timing gear assembly from the camshaft.
      GTY632584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
      NOTE:
      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.
      • Do not disassemble the camshaft timing gear assembly.
  28. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Using a wrench to hold the hexagonal portion of the camshaft, remove the bolt and camshaft timing exhaust gear assembly from the No. 2 camshaft.
      GTY628086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
      NOTE:
      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.
      • Do not disassemble the camshaft timing exhaust gear assembly.
  29. REMOVE OIL PIPE SUB-ASSEMBLY 
    1. Remove the bolt and oil pipe sub-assembly from the No. 4 camshaft bearing cap.
      GTY501916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY 
    1. Uniformly loosen and remove the 22 bearing cap bolts in the order shown in the illustration.
      Fig 1: Camshaft Housing Sub-Assembly Bolts Loosening Sequence
      GTY510749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly.
      GTY642434Courtesy 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.

  31. REMOVE NO. 3 WATER BY-PASS PIPE 
    1. Remove the 3 bolts, No. 3 water by-pass pipe and gasket from the cylinder head sub-assembly.
      GTY642436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE CAMSHAFT BEARING CAP 
    1. Remove the 11 bearing cap bolts in the order shown in the illustration.
      Fig 2: Bearing Cap Bolts Loosening Sequence
      GTY510286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap from the camshaft housing sub-assembly.

      HINT: 

      Arrange the removed parts in the correct order.

  33. REMOVE OIL CONTROL VALVE FILTER 
    1. Remove the oil control valve filter from the No. 1 camshaft bearing cap.
      GTY501913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE CAMSHAFT 
    1. Remove the camshaft from the camshaft housing sub-assembly.
  35. REMOVE NO. 2 CAMSHAFT 
    1. Remove the No. 2 camshaft from the camshaft housing sub-assembly.
  36. REMOVE NO. 1 CAMSHAFT BEARING 
    1. Remove the No. 1 camshaft bearing from the No. 1 camshaft bearing cap.
      GTY501921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE NO. 2 CAMSHAFT BEARING 
    1. Remove the No. 2 camshaft bearing from the camshaft housing sub-assembly.
      GTY501923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. 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 the correct order.

  39. 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 the correct order.

  40. REMOVE VALVE STEM CAP 
    1. Remove the 16 valve stem caps from the cylinder head sub-assembly.

      HINT: 

      Arrange the removed parts in the correct order.

  41. REMOVE CYLINDER HEAD SUB-ASSEMBLY 

    See step  36

  42. REMOVE CYLINDER HEAD GASKET 

    See step  37

  43. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    1. Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.
      GTY653814Courtesy 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.

  44. REMOVE OIL FILTER CAP ASSEMBLY 

    Refer to PROCEDURE - Step 2 [10/2015 - 11/2019] , or refer to PROCEDURE - Step 2 [11/2019 - 11/2021] , or refer to PROCEDURE - Step 2 [11/2021 - ]

  45. REMOVE OIL FILTER BRACKET CLIP 
    1. Remove the oil filter bracket clip from the stiffening crankcase assembly.
      GTY642433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE OIL COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 3

  47. REMOVE OIL PAN DRAIN PLUG 
    1. Remove the oil pan drain plug and gasket from the oil pan sub-assembly.
  48. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Remove the 11 bolts and 2 nuts.
      GTY679098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      GTY145991Courtesy 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 stiffening crankcase assembly flange.
  49. REMOVE ENGINE OIL LEVEL SENSOR 

    Refer to PROCEDURE - Step 3

  50. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the 3 bolts, oil strainer sub-assembly and gasket from the stiffening crankcase assembly and engine balancer assembly.
      GTY642444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE NO. 1 OIL PAN BAFFLE PLATE 
    1. Remove the 4 bolts and No. 1 oil pan baffle plate from the engine balancer assembly.
      GTY679097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE ENGINE BALANCER ASSEMBLY 
    1. Remove the 5 bolts and engine balancer assembly from the stiffening crankcase assembly.
      GTY642440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not disassemble the engine balancer assembly.

  53. REMOVE ENGINE OIL TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 3

  54. REMOVE STIFFENING CRANKCASE ASSEMBLY 
    1. Remove the 8 bolts.
      GTY642430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      GTY642428Courtesy 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 REAR ENGINE OIL SEAL 
    1. Remove the rear engine oil seal from the cylinder block sub-assembly.
  56. REMOVE STUD BOLT 
    NOTE:

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

  57. REMOVE RING PIN 

    HINT: 

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

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