Engine Unit: Disassembly

REMOVE ENGINE HANGER
1. Remove the 2 bolts and 2 engine hangers.
  
  Fig 1: Locating Bolts And Engine Hangers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL FILLER CAP SUB-ASSEMBLY
1. Remove the oil filler cap.
  
  Fig 2: Locating Oil Filler Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL FILLER CAP GASKET
1. Remove the oil filler cap gasket.
  
  Fig 3: Locating Oil Filler Cap Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPARK PLUG
1. Using a 14 mm socket wrench, remove the 4 spark plugs.
  
  Fig 4: Removing Spark Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT POSITION SENSOR
1. Remove the 2 bolts and 2 sensors.
  
  Fig 5: Locating Bolts And Sensors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Remove the 2 bolts, 2 O-rings, bracket and 2 oil control valves.
  
  Fig 6: Locating Bolts, O-Rings, Bracket And Oil Control Valves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
1. Remove the 13 bolts, seal washer and cylinder head cover.
  
  Fig 7: Locating Bolts, Seal Washer And Cylinder Head Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 gaskets from the camshaft bearing cap.
  NOTE: When removing the cylinder head cover, some of the gaskets may stick to it so be careful not to drop any of the gaskets into the engine.
  
  Fig 8: Locating Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER GASKET
1. Remove the cylinder head cover gasket.
  
  Fig 9: Identifying Cylinder Head Cover Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SET NO. 1 CYLINDER TO TDC / COMPRESSION
1. Turn the crankshaft pulley, and align its timing notch with the "0" timing mark on the timing chain cover sub-assembly.
2. Check that timing marks on both the camshaft timing exhaust gear and camshaft timing gear are facing upward, as shown in the illustration.
  HINT:
  
  If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.
  
  Fig 10: Identifying Timing Marks On Camshaft Timing Exhaust Gear And Camshaft Timing Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT PULLEY
1. Using SST, hold the pulley in place and loosen the pulley bolt.
  SST 09213-58013 (91651-60855), 09330-00021
  
  Fig 11: Loosening Pulley Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the pulley bolt and pulley.
  SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
  
  Fig 12: Removing Pulley Bolt And Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
1. Remove the 2 nuts, bracket, No. 1 chain tensioner assembly and gasket.
  NOTE: Do not turn the crankshaft after you have removed the chain tensioner.
  
  Fig 13: Locating No. 1 Chain Tensioner Assembly And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT POSITION SENSOR
1. Remove the bolt and crankshaft position sensor.
  
  Fig 14: Locating Bolt And Crankshaft Position Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
1. Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
  
  Fig 15: Locating Engine Oil Pressure Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 TAPER SCREW PLUG
1. Remove the No. 1 taper screw plug.
  
  Fig 16: Locating No. 1 Taper Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE KNOCK SENSOR
1. Remove the bolt and knock sensor.
  
  Fig 17: Locating Bolt And Knock Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE WATER TEMPERATURE SENSOR
1. Using a 19 mm deep socket wrench, remove the engine water temperature sensor.
2. Remove the gasket from the engine water temperature sensor.
  
  Fig 18: Identifying Engine Water Temperature Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL FILTER SUB-ASSEMBLY
1. Using SST, remove the oil filter cap.
  SST 09228-06501
  
  HINT:
  
  Use a container to catch the draining oil. After the oil filter cap is loosened approximately 4 turns and the cap rib is facing straight down, engine oil will begin to drain from the gap between the oil filter cap and oil pan.
  
  Fig 19: Removing Oil Filter Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the oil filter element and O-ring from the oil filter cap.
  NOTE: Be sure to remove the O-ring (for the cap) by hand, without using any tools, to prevent damage to the O-ring groove on the cap.
  
  Fig 20: Identifying Oil Filter Element And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER INLET
1. Remove the 2 nuts and remove the water inlet.
  
  Fig 21: Locating Nuts And Water Inlet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE THERMOSTAT
1. Remove thermostat from the cylinder block.
2. Remove the gasket from thermostat.
  
  Fig 22: Locating Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
1. Remove the 3 bolts and remove the engine mounting bracket RH.
  
  Fig 23: Locating Bolts And Engine Mounting Bracket RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 bolts and remove the oil filter bracket.
  
  Fig 24: Locating Bolts And Oil Filter Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 O-rings from the timing chain cover sub-assembly.
  
  Fig 25: Locating O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 19 bolts.
  
  Fig 26: Locating Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the timing chain or belt cover sub-assembly by prying between the timing chain or belt cover sub-assembly and cylinder head or cylinder block with a screwdriver wrapped in protective tape.
  NOTE: Be careful not to damage the contact surfaces of the timing chain or belt cover sub-assembly, cylinder block and cylinder head.
  
  Fig 27: Prying Timing Chain Or Belt Cover Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the 3 O-rings from the cylinder head and cylinder block.
  
  Fig 28: Locating O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the 3 bolts and the water pump assembly.
  
  Fig 29: Locating Bolts And Water Pump Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the gasket from the timing chain or belt cover sub-assembly.
  
  Fig 30: Identifying Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER INLET HOUSING
1. Remove the 3 bolts, gasket and water inlet housing.
  
  Fig 31: Locating Bolts, Gasket And Water Inlet Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 GENERATOR BRACKET
1. Remove the 4 bolts and generator bracket.
  
  Fig 32: Locating Bolts And Generator Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CHAIN VIBRATION DAMPER
1. Remove the 2 bolts and remove the No. 2 chain vibration damper.
  
  Fig 33: Locating Bolts And No. 2 Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CHAIN TENSIONER SLIPPER
1. Remove the chain tensioner slipper from the cylinder block.
  
  Fig 34: Identifying Chain Tensioner Slipper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN VIBRATION DAMPER
1. Remove the 2 bolts and the chain vibration damper.
  
  Fig 35: Locating Bolts And Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CHAIN SUB-ASSEMBLY
1. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to loosen the chain on the camshaft timing gears.
2. With the chain loosened, release the chain from the camshaft timing gear assembly and rest it on the camshaft timing gear assembly.
  HINT:
  
  Be sure to release the chain from the sprocket completely.
3. Turn the camshaft clockwise to return it to the original position and remove the chain.
REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
1. Remove the crankshaft timing gear or sprocket.
  
  Fig 37: Locating Crankshaft Timing Gear Or Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CHAIN SUB-ASSEMBLY
1. Turn the crankshaft 90° clockwise to align the adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
  
  Fig 38: Turning Crankshaft 90° Clockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Insert a 4 mm diameter bar into the adjusting hole of the oil pump drive shaft gear to lock the gear in position, and then remove the nut.
  
  Fig 39: Identifying Bar Into Adjusting Hole Of Oil Pump Drive Shaft Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the bolt, chain tensioner plate and spring.
  
  Fig 40: Identifying Bolt, Chain Tensioner Plate And Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the oil pump drive shaft gear, oil pump drive gear and chain.
  
  Fig 41: Identifying Oil Pump Drive Shaft Gear, Oil Pump Drive Gear And Chain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE
1. Remove the No. 1 crankshaft position sensor plate.
  
  Fig 42: Identifying No. 1 Crankshaft Position Sensor Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT TIMING GEAR KEY
1. Using a screwdriver, remove the 2 crankshaft timing gear keys.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 43: Removing Crankshaft Timing Gear Keys
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
1. Check the lock of the camshaft timing gear.
2. Release the lock pin.
  NOTE: Before removing the camshaft timing gear assembly, make sure that the lock pin has been released.
  1. After cleaning and degreasing the VVT oil hole on the intake side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.
    NOTE: Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.
    
    Fig 44: Identifying Adhesive Tape Sealing Area
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A)
  3. Apply approximately 150 kPa (1.5 kgf/ cm² , 22 psi) of air pressure to the hole pricked in procedure A to release the lock pin.
    NOTE:
    If air leaks out, reattach the adhesive tape.
    
    Cover the oil hole with a shop rag or piece of cloth when applying air pressure to prevent oil from spraying.
    
    Do not lock the camshaft timing gear assembly. If it is locked, release the lock pin again.
    
    Fig 45: Applying Air Pressure To Hole
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    HINT:
    - The camshaft timing gear assembly may be turned in the advance direction without applying any force.
    - If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.
  4. Remove the adhesive tape from the No. 1 camshaft bearing cap.
3. Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing gear assembly.
  NOTE:
  - Before removing the camshaft timing gear, make sure that the lock pin has been released.
  - Be sure not to remove the other 4 bolts.
  - Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.
    
    Fig 46: Identifying Flange Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
1. Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing exhaust gear assembly.
  NOTE:
  - Be sure not to remove the other 4 bolts.
  - Keep the camshaft timing exhaust gear assembly horizontal while removing it from the camshaft.
    
    Fig 47: Identifying Flange Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT BEARING CAP
1. Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
  
  Fig 48: Locating Bearing Cap Bolts And Removal Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen and remove the 15 bearing cap bolts in the sequence shown in the illustration.
  NOTE: Uniformly loosen the bolts while keeping the camshaft level.
  
  Fig 49: Locating Bearing Cap Bolts And Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 5 bearing caps.
  HINT:
  
  Arrange the removed parts in the correct order.
4. Remove the camshaft and No. 2 camshaft.
REMOVE CAMSHAFT
1. Remove the camshaft.
  
  Fig 50: Identifying Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CAMSHAFT
1. Remove the No. 2 camshaft.
  
  Fig 51: Identifying No. 2 Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Remove the 16 valve rocker arms.
  HINT:
  
  Arrange the removed parts in the correct order.
  
  Fig 52: Identifying Valve Rocker Arms
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE LASH ADJUSTER ASSEMBLY
1. Remove the 16 valve lash adjusters from the cylinder head.
  HINT:
  
  Arrange the removed parts in the correct order.
  
  Fig 53: Identifying Valve Lash Adjusters
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL CONTROL VALVE FILTER
1. Remove the oil control valve filter.
  
  Fig 54: Removing Oil Control Valve Filter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CAMSHAFT BEARING
1. Remove the 2 No. 1 camshaft bearings.
  HINT:
  
  Arrange the removed parts in the correct order.
  
  Fig 55: Identifying No. 1 Camshaft Bearings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CAMSHAFT BEARING
1. Remove the 2 No. 2 camshaft bearings.
  HINT:
  
  Arrange the removed parts in the correct order.
  
  Fig 56: Identifying No. 2 Camshaft Bearings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY
1. Remove the 2 bolts.
  
  Fig 57: Locating Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.
  NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.
  
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 58: Removing Camshaft Housing By Prying
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD SUB-ASSEMBLY
1. Using several steps, loosen and remove the 10 cylinder head bolts uniformly with a 10 mm bi-hexagon wrench in the sequence shown in the illustration.
  Remove the 10 cylinder head bolts and the plate washers.
  NOTE:
  - Do not drop the washers into the cylinder head.
  - Head warpage or cracking could result from removing bolts in the wrong order.
2. Remove the cylinder head sub-assembly.
REMOVE CYLINDER HEAD GASKET
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Remove the water drain cock plug from the water drain cock assembly.
2. Remove the water drain cock assembly from the cylinder block.
REMOVE VENTILATION VALVE SUB-ASSEMBLY
1. Remove the ventilation valve.
  
  Fig 61: Locating Ventilation Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PAN DRAIN PLUG
1. Remove the oil pan drain plug and gasket.
  
  Fig 62: Locating Oil Pan Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
1. Remove the 10 bolts and 2 nuts.
  
  Fig 63: Locating Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the blade of oil pan seal cutter between the No. 2 oil pan sub-assembly and stiffening crankcase assembly, and cutoff the applied sealer and remove the No. 2 oil pan sub-assembly.
  NOTE: Do not damage the No. 2 oil pan sub-assembly or stiffening crankcase assembly.
  
  Fig 64: Inserting Oil Pan Seal Cutter Between No. 2 Oil Pan Sub-Assembly And Stiffening Crankcase Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PUMP ASSEMBLY
1. Remove the 3 bolts and remove the oil pump assembly.
  
  Fig 65: Locating Bolts And Oil Pump Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STIFFENING CRANKCASE ASSEMBLY
1. Remove the 11 bolts.
  
  Fig 66: Locating Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver with its tip wrapped in protective tape, remove the crankcase by prying between the crankcase and cylinder block.
  NOTE: Be careful not to damage the contact surfaces of the crankcase and cylinder block.
  
  Fig 67: Removing Crankcase By Prying
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002