Disassembly [12/2023 - ]: Procedure

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 7

Refer to PROCEDURE - Step 9

Refer to PROCEDURE - Step 10

Refer to PROCEDURE - Step 11

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1

   Cylinder Block Water Drain Cock Plug

   *2

   Cylinder Block Water Drain Cock Sub-assembly

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Refer to PROCEDURE - Step 17

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using a screwdriver with its tip wrapped with protective tape as shown in the illustration, deform each spark plug tube gasket inwards and remove the 6 spark plug tube gaskets from the cylinder head cover sub-assembly and cylinder head cover sub-assembly LH.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Refer to PROCEDURE - Step 5

Refer to PROCEDURE - Step 6

Refer to PROCEDURE - Step 7

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Bolt

   Nut

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Refer to PROCEDURE - Step 3

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Bolt

   Nut

   1. Remove the 15 bolts and 2 nuts.
   2. Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and No. 2 oil pan sub-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 No. 2 oil pan sub-assembly and oil pan sub-assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Refer to PROCEDURE - Step 7

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Center Line

   *b

   Crankshaft Timing Gear or Sprocket Key Groove

   1. Temporarily tighten the crankshaft pulley set bolt to the crankshaft.
   2. Turn the crankshaft clockwise to align the timing mark of the crankshaft timing gear or sprocket key groove with the center line of the block bore (for Bank 1) (TDC/compression).

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Timing Mark

   *b

   Viewpoint

   1. Check that the timing marks of the camshaft timing gear assemblies and camshaft timing exhaust gear assemblies are aligned with the timing marks of the camshaft bearing caps as shown in the illustration.
      NOTE:

      • Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear assembly and each camshaft timing exhaust gear assembly.
      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

      HINT: 

      • If not aligned, turn the crankshaft 1 revolution (360°) clockwise and align the timing marks as shown in the illustration.

      • Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        *a	Timing Mark

        For the camshaft or No. 3 camshaft sub-assembly:

        Be sure to check the mark (A) at the point where the marks (B) and (C) are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Plunger	*b	Stopper Plate
   *c	Pin	-	-

   1. Turn the stopper plate clockwise to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.
   2. Turn the stopper plate counterclockwise to set the lock, and insert a 1.0 mm (0.0394 in.) diameter pin into the hole of the stopper plate.
   3. Remove the 2 bolts and No. 1 chain tensioner assembly from the cylinder head sub-assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *A	for Bank 1	-	-
   *a	Center Line	*b	Crankshaft Timing Gear or Sprocket Key Groove
   *c	Mark	*d	10°

   1. Turn the crankshaft 10° counterclockwise to loosen the chain sub-assembly of the crankshaft timing gear or sprocket.
   2. Remove the crankshaft pulley set bolt from the crankshaft.
   3. Remove the chain sub-assembly from the crankshaft timing gear or sprocket and place it on the crankshaft.
   4. Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) so that it is positioned as shown in the illustration.
      NOTE:

      Be sure to loosen the chain sub-assembly between the banks.

   5. Remove the chain sub-assembly from the engine assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	No. 2 Idle Gear Shaft	*2	Idle Sprocket Assembly
   *3	No. 1 Idle Gear Shaft	-	-

   1. Using a 10 mm hexagon socket wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft from the cylinder block sub-assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using a screwdriver with its tip wrapped with protective tape, remove the 2 crankshaft timing gear keys from the crankshaft.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Camshaft Timing Gear Assembly	*2	Camshaft Timing Exhaust Gear Assembly
   *3	No. 2 Chain Sub-assembly	-	-
   *a	Pin	*b	Plunger
   *c	Push	*d	Hold
   *e	Turn	-	-

   1. While pushing the No. 2 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the hole to secure the No. 2 chain tensioner assembly.
   2. Using a wrench to hold the hexagonal portion of camshaft, loosen the camshaft timing gear bolt of the camshaft timing gear assembly.
      NOTE:

      • Be careful not to damage the camshaft, camshaft housing sub-assembly RH or spark plug tube with the wrench.
      • Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.
      • If the camshaft timing gear bolt has been struck or dropped, replace it.
   3. Using a wrench to hold the hexagonal portion of No. 2 camshaft, loosen the camshaft timing gear bolt of the camshaft timing exhaust gear assembly.
      NOTE:

      • Be careful not to damage the No. 2 camshaft, camshaft housing sub-assembly RH or spark plug tube with the wrench.
      • Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.
      • If the camshaft timing gear bolt has been struck or dropped, replace it.
   4. Remove the 2 camshaft timing gear bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly together with the No. 2 chain sub-assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Fig 1: Camshaft Bearing Cap (For Bank 1) Loosening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Straight Pin	*b	Front View
   *c	45°	-	-

   1. Check that the camshaft and No. 2 camshaft are positioned as shown in the illustration.
   2. Uniformly loosen and remove the 9 bolts in several steps in the order shown in the illustration.
   3. Uniformly loosen and remove the 15 bolts in several steps in the order shown in the illustration.
      NOTE:

      Make sure that the camshaft and No. 2 camshaft remains level while uniformly loosening the bolts.

   4. Remove the fuel pump lifter housing from the camshaft housing sub-assembly RH.
   5. Remove the 5 camshaft bearing caps from the camshaft housing sub-assembly RH.
   6. Remove the 2 oil control valve filters from the 2 camshaft bearing caps.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the camshaft housing sub-assembly RH by prying between the cylinder head sub-assembly and camshaft housing sub-assembly RH 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 RH.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Camshaft Timing Gear Assembly	*2	Camshaft Timing Exhaust Gear Assembly
   *3	No. 2 Chain Sub-assembly	-	-
   *a	Pin	*b	Plunger
   *c	Push	*d	Hold
   *e	Turn	-	-

   1. While pushing down the No. 3 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the hole to secure the No. 3 chain tensioner assembly.
   2. Using a wrench to hold the hexagonal portion of No. 3 camshaft sub-assembly, loosen the camshaft timing gear bolt of the camshaft timing gear assembly.
      NOTE:

      • Be careful not to damage the No. 3 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.
      • Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.
      • If the camshaft timing gear bolt has been struck or dropped, replace it.
   3. Using a wrench to hold the hexagonal portion of No. 4 camshaft sub-assembly, loosen the camshaft timing gear bolt of the camshaft timing exhaust gear assembly.
      NOTE:

      • Be careful not to damage the No. 4 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.
      • Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.
      • If the camshaft timing gear bolt has been struck or dropped, replace it.
   4. Remove the 2 camshaft timing gear bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly together with the No. 2 chain sub-assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Fig 2: Camshaft Bearing Cap (For Bank 2) Loosening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Straight Pin

   *b

   Front View

   1. Check that the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly are positioned as shown in the illustration.
   2. Uniformly loosen and remove the 8 bolts in several steps in the order shown in the illustration.
   3. Uniformly loosen and remove the 15 bolts in several steps in the order shown in the illustration.
      NOTE:

      Make sure that the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly remains level while uniformly loosening the bolts.

   4. Remove the 5 camshaft bearing caps from the camshaft housing sub-assembly LH.
   5. Remove the 2 oil control valve filters from the 2 camshaft bearing caps.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the camshaft housing sub-assembly LH by prying between the cylinder head LH and camshaft housing sub-assembly LH with a screwdriver with its tip wrapped with protective tape.
      NOTE:

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the 24 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly and cylinder head LH.

      HINT: 

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the 24 valve lash adjuster assemblies from the cylinder head sub-assembly and cylinder head LH.

      HINT: 

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the 24 valve stem caps from the cylinder head sub-assembly and cylinder head LH.

      HINT: 

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the 6 bolts.
   2. Using a screwdriver with its tip wrapped with protective tape, pry out the rear engine oil seal retainer.
      NOTE:

      Be careful not to damage the rear engine oil seal retainer.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Place the rear engine oil seal retainer on wooden blocks.
   2. Using a hammer and a screwdriver with its tip wrapped with protective tape, tap out the rear engine oil seal.
      NOTE:

      Be careful not to damage the rear engine oil seal retainer.

1. Fig 3: Cylinder Head Sub-Assembly Loosening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Using a 10 mm bi-hexagon socket wrench, uniformly loosen the 8 cylinder head set bolts in the order shown in the illustration. Remove the 8 cylinder head set bolts and 8 cylinder head set plate washers.
      NOTE:

      • Be careful not to drop cylinder head set plate washers into the cylinder head sub-assembly.
      • Warpage or cracking of the cylinder head sub-assembly may result from removing 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.

Refer to PROCEDURE - Step 93

1. Fig 4: Cylinder Head LH Loosening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Uniformly loosen and remove the 2 bolts in several steps in the order shown in the illustration.
   2. Using a 10 mm bi-hexagon socket wrench, uniformly loosen the 8 cylinder head set bolts in the order shown in the illustration. Remove the 8 cylinder head set bolts and 8 cylinder head set plate washers.
      NOTE:

      • Be careful not to drop cylinder head set plate washers into the cylinder head LH.
      • Warpage or cracking of the cylinder head LH may result from removing 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.

   3. Remove the cylinder head LH from the cylinder block sub-assembly.

Refer to PROCEDURE - Step 95

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using an E6 "TORX" socket wrench, remove the 4 stud bolts from the oil pan sub-assembly.
   2. Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the oil pan sub-assembly.

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the engine mounting bracket RH.

3. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the No. 1 oil cooler bracket.

4. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using an E7 "TORX" socket wrench, remove the stud bolt from the cylinder block sub-assembly.
   2. Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the cylinder block sub-assembly.