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Engine Unit: Disassembly

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE SPARK PLUG 
    1. Using a spark plug wrench, remove the 4 spark plugs.
      Fig 1: Identifying Spark Plugs
      G04828827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE KNOCK SENSOR 
    1. Remove the nut and remove the knock sensor.
      Fig 2: Locating Knock Sensor
      G04828828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Using a 24 mm deep socket wrench, remove the oil pressure switch.
      Fig 3: Locating Oil Pressure Switch
      G04828829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using SST, remove the engine coolant temperature sensor.

      SST 09817-33190 

      Fig 4: Identifying Engine Coolant Temperature Sensor With SST
      G04828830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE WATER INLET 
    1. Remove the 2 nuts and remove the water inlet.
      Fig 5: Locating Water Inlet
      G04828831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE THERMOSTAT 
    1. Remove the thermostat.
    2. Remove the gasket from the thermostat.
      Fig 6: Identifying Thermostat
      G04828832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
    1. Remove the oil filler cap from the cylinder head cover.
      Fig 7: Identifying Oil Filler Cap From Cylinder Head Cover
      G04828833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE OIL FILLER CAP GASKET 
    1. Using a screwdriver, remove the gasket from the oil filler cap.
  9. REMOVE CRANKSHAFT POSITION SENSOR 
    1. Remove the bolt and the crankshaft position sensor.
      Fig 8: Removing Gasket From Oil Filler Cap
      G04828834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE VENTILATION VALVE SUB-ASSEMBLY 
    1. Remove the ventilation valve from the cylinder head cover.
      Fig 9: Identifying Ventilation Valve From Cylinder Head Cover
      G04828835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 9 bolts, 2 nuts and 2 seal washers and then remove the cylinder head cover sub-assembly.
  12. REMOVE CYLINDER HEAD COVER GASKET 
    1. Remove the gasket from the cylinder head cover.
      Fig 10: Locating Cylinder Head Cover Bolts
      G04828836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
    1. Remove the bolt and the camshaft timing oil control valve.
  14. REMOVE OIL LEVEL GAUGE GUIDE 
    1. Remove the bolt and the oil level gauge guide.
      Fig 11: Locating Camshaft Timing Oil Control Valve
      G04828837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE WATER PUMP PULLEY 
    1. Using SST, hold the pump pulley.

      SST 09960-10010 (09962-01000, 09963-00700) 

    2. Remove the 3 bolts and the pump pulley.
      Fig 12: Locating Pump Pulley And SST
      G04828838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY 
    1. Set cylinder No. 1 to TDC/compression.
      1. Turn the crankshaft damper sub-assembly, and align its timing notch with timing mark "0" of the oil pump.
        Fig 13: Identifying Timing Notch
        G04828482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Check that the timing marks on the camshaft timing sprocket and the camshaft timing gear are all facing upward, as shown in the illustration.

        If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

        Fig 14: Identifying Timing Marks
        G04828483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using 2 SSTs, loosen the bolt while holding the crankshaft damper sub-assembly.

      SST 09213-14010 (91651-60865), 09330-00021 

      NOTE: Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump assembly.
    3. Remove the SSTs and the bolt.
    4. Remove the crankshaft damper sub-assembly.
      Fig 15: Loosening Bolt While Holding Crankshaft Damper Sub-Assembly
      G04828841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE TRANSVERSE ENGINE, ENGINE MOUNTING BRACKET 
    1. Remove the 4 bolts and remove the transverse engine mounting bracket.
      Fig 16: Locating Transverse Engine Mounting Bracket
      G04828842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE WATER PUMP ASSEMBLY 
    1. Remove the 3 bolts and the 2 nuts and remove the water pump and the gasket.
      Fig 17: Locating Water Pump Assembly
      G04828843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE OIL PUMP ASSEMBLY 
    1. Remove the 15 bolts and the nut.
      Fig 18: Locating Oil Pump Assembly
      G04828844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver with its tip wrapped in protective tape, prize the oil pump assembly to remove it.
      NOTE: Do not damage the contact surface of the oil pump assembly and oil pan sub-assembly.
      Fig 19: Removing Oil Pump Assembly
      G04828845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 O-rings from the cylinder block and oil pan sub-assembly.
      Fig 20: Locating O-Rings From Cylinder Block And Oil Pan Sub-Assembly
      G04828846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE OIL PUMP SEAL 
    1. Using a screwdriver with its tip wrapped in tape, remove the oil seal.
  21. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1 
    NOTE:
    • Do not rotate the crankshaft with the chain tensioner removed.
    • When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.
      Fig 21: Removing Oil Pump Seal
      G04828847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pull up the stopper plate and hold it with its lock released.
      Fig 22: Identifying Stopper Plate
      G04828848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Unlock the plunger of the tensioner and push it in to the end.
      Fig 23: Identifying Stopper Plate
      G04828849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Pull down the stopper plate with the plunger pushed to the end and lock the plunger.
      Fig 24: Identifying Stopper Plate
      G04828525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Insert a 3 mm (0.12 in.) diameter bar into the hole in the stopper plate and lock the plunger.
      Fig 25: Identifying Stopper Plate And Lock Plunger
      G04828528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 bolts and remove chain tensioner assembly No. 1.
      Fig 26: Locating Chain Tensioner Assembly
      G04828529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE CHAIN TENSIONER SLIPPER 
    1. Remove the chain tensioner slipper.
      Fig 27: Identifying Chain Tensioner Slipper
      G04828530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE CHAIN VIBRATION DAMPER NO. 1 
    1. Remove the 2 bolts and remove chain vibration damper No. 1.
  24. REMOVE CHAIN SUB-ASSEMBLY 
    Fig 28: Locating Chain Vibration Damper And Bolts
    G04828531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 
    1. Remove the 3 bolts and remove the fuel delivery pipe sub-assembly with 4 fuel injectors.
      NOTE: Do not drop the fuel injectors when removing the fuel delivery pipe sub-assembly.
      Fig 29: Locating Fuel Delivery Pipe Sub-Assembly
      G04828855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE DELIVERY PIPE NO. 1 SPACER 
    1. Remove the 2 delivery pipe No. 1 spacers.
      Fig 30: Locating Delivery Pipe Spacers
      G04828856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE INJECTOR VIBRATION INSULATOR 
    1. Remove the 4 injector vibration insulators.
      Fig 31: Locating Injector Vibration Insulators
      G04828857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE FUEL INJECTOR ASSEMBLY 
    1. Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly.
      Fig 32: Pulling Fuel Injector Assemblies
      G04828858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE CAMSHAFT POSITION SENSOR 
    1. Remove the bolt and the camshaft position sensor.
  30. REMOVE NO. 2 CAMSHAFT 
    NOTE: When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.
    Fig 33: Locating Camshaft Position Sensor And Bolt
    G04828859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using several steps, uniformly loosen and remove the 11 bearing cap bolts in the sequence shown in the illustration, then remove camshaft bearing cap No. 1, camshaft bearing cap No. 2 and camshaft No. 2.
      NOTE: Loosen each bolt uniformly while keeping the camshaft level.
      Fig 34: Identifying Camshaft Bearing Cap Sequence
      G04828860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE CAMSHAFT TIMING SPROCKET 
    1. Clamp the camshaft in a vice.
    2. Remove the flange bolt and the camshaft timing sprocket.
      NOTE: Do not damage the camshaft.
      Fig 35: Locating Flange Bolt
      G04828861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE CAMSHAFT 
    1. Using several steps, uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration, then remove camshaft bearing cap No. 2 and the camshaft.
      NOTE: Loosen each bolt uniformly while keeping the camshaft level.
      Fig 36: Identifying Bearing Cap Bolts Sequence
      G04828862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Clamp the camshaft in a vise, and confirm that it is locked.
      NOTE: Do not damage the camshaft.
    2. Cover the 4 oil paths of the cam journal with tape as shown in the illustration.

      HINT:

      One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with a piece of rubber before wrapping the cam journal with the tape.

    3. Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path.
      Fig 37: Identifying Cam Journal With Tape
      G04828562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply about 150 kPa (1.5 kgf*cm2 ) air pressure into the 2 broken paths (the advance side path and the retard side path).
      NOTE: Cover the paths with a shop rag or piece of cloth to prevent oil splashes.
      Fig 38: Applying Air Pressure Advance Side Path And Retard Side Path
      G04828563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced.

      HINT:

    6. The lock pin is released and the camshaft timing gear revolves in the advance direction. When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path.
      NOTE: Camshaft timing gear assembly occasionally shifts to the retard side abruptly if the air pressure on the advance side path is released first. This often results in breakage of the lock pin.
      Fig 39: Applying Air Pressure On Advance Side, Side Path Retard Side, Side Path
      G04828564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the flange bolt and remove the camshaft timing gear assembly.
      NOTE:
      • Do not remove the other 4 bolts.
      • When reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first.
        Fig 40: Identifying Camshaft Timing Gear Assembly And Flange Bolt
        G04828565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE CYLINDER HEAD SUB-ASSEMBLY 
    1. Using several steps, uniformly loosen and remove the 10 cylinder head bolts with an 8 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.
        Fig 41: Identifying Cylinder Head Bolts
        G04828867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE CYLINDER HEAD GASKET 
  36. REMOVE OIL FILTER SUB-ASSEMBLY 
    1. Using SST, remove the oil filter.

      SST 09228-06501 

      Fig 42: Removing Oil Filter With SST
      G04828868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE OIL FILTER UNION 
    1. Using a 12 mm hexagon wrench, remove the oil filter union.
      Fig 43: Identifying Oil Filter Union
      G04828869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE ENGINE REAR OIL SEAL 
    1. Using a knife, cut off the oil seal lip.
    2. Using a screwdriver with its tip wrapped in protective tape, pry out the oil seal.
      NOTE: After removal, check the crankshaft for any damage. If damaged, smooth the surface with 400-grit sandpaper.
  39. REMOVE OIL PAN SUB-ASSEMBLY NO. 2 
    1. Remove the oil pan drain plug and gasket.
      Fig 44: Removing Engine Rear Oil Seal
      G04828870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 9 bolts and 2 nuts.
      Fig 45: Removing Oil Pan Sub-Assembly
      G04828871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Insert the blade of SST between oil pan No. 1 and oil pan No. 2, and cut off the applied sealer and remove oil pan No. 2.

      SST 09032-00100 

      NOTE: Do not damage oil pan No. 1 or oil pan No. 2.
  40. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the bolt and 2 nuts.
    2. Remove the oil strainer and the gasket.
      Fig 46: Removing Oil Strainer And Gasket
      G04828872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Loosen and remove the 13 bolts uniformly in several steps.
      Fig 47: Locating Oil Pan Sub-Assembly Bolts
      G04828873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove oil pan No. 1 by prying between the cylinder block and oil pan No. 1.
      NOTE: Do not damage the contact surfaces of oil pan No. 1 or the cylinder block.
    3. Remove the 2 O-rings from the cylinder block.
      Fig 48: Locating Cylinder Block And Oil Pan
      G04828874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE STUD BOLT 
    1. Remove the 4 stud bolts.
      Fig 49: Identifying Stud Bolts
      G04828875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD 
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
    2. Push the piston, connecting rod assembly and upper bearing down through the top of the cylinder block to remove them.

      HINT:

      • Keep the bearing, connecting rod and cap together.
      • Keep the piston and the connecting rod assemblies in the correct order so that they can be returned to their original locations when reassembled.
        Fig 50: Removing Top Of Cylinder
        G04828876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE CONNECTING ROD BEARING 
  45. REMOVE CRANKSHAFT 
    1. Using several steps, loosen and remove the 10 bearing cap sub-assembly bolts uniformly with SST in the sequence shown in the illustration.

      SST 09011-38121 

    2. Remove the bearing cap and the crankshaft.
  46. REMOVE CRANKSHAFT BEARING 
  47. REMOVE CRANKSHAFT THRUST WASHER UPPER 
  48. REMOVE PISTON RING SET 
    NOTE: Keep the piston rings in the correct combination and correct order so that they can be returned to their original locations when reassembled.
    Fig 51: Identifying Crankshaft Bearing And Bolts
    G04828877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a piston ring expander, remove the 2 compression rings.
    2. Remove the 2 side rails and the oil ring by hand.
      Fig 52: Removing Side Rails And Oil Ring
      G04828878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE WITH PIN PISTON SUB-ASSEMBLY 
    1. Using SST, press the piston pin out of the piston.

      SST 09221-25026 (09221-00021, 09221-00030, 09221-00090, 09221-00150, 09221-00100) 

      NOTE: Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they can be returned to their original locations when reassembled.
      Fig 53: Identifying Connecting Rod, Piston Pin And SST
      G04828879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
  51. REMOVE STUD BOLT 
    1. Using "Torx" socket wrench E5, remove the 7 stud bolts.
  52. REMOVE RING PIN 
  53. REMOVE STRAIGHT PIN 
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