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Engine Unit: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE ENGINE COVER JOINT 
    1. Remove the 3 joints.
  2. REMOVE SPARK PLUG  (See REMOVAL )
  3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)  (See INSPECTION )
  4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)  (See INSPECTION )
    Fig 1: Locating Engine Cover Joint
    G05997952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)  (See REMOVAL )
  6. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)  (See REMOVAL )
  7. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
    1. Remove the oil filler cap from the cylinder head.
    2. Remove the gasket from the oil filler cap.
  8. REMOVE CRANKSHAFT POSITION SENSOR  (See REMOVAL )
  9. REMOVE VENTILATION VALVE SUB-ASSEMBLY  (See PCV VALVE )
  10. REMOVE VENTILATION CASE SUB-ASSEMBLY 
    1. Remove the 8 bolts and 2 nuts.
      Fig 2: Locating Ventilation Case Sub-Assembly Bolts And Nuts
      G06030244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the ventilation case by prying between the ventilation case and cylinder block with a screwdriver.

      HINT:

      Tape the screwdriver tip before use.

      NOTE: Be careful not to damage the contact surfaces of the cylinder block and ventilation case.
      Fig 3: Locating Contact Surfaces Of Cylinder Block And Ventilation Case
      G06030245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE SEPARATOR CASE 
    1. Remove the 2 bolts, separator case and gasket.
    Fig 4: Identifying Separator Case Bolts And Gasket
    G06030246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 1 WATER BY-PASS PIPE 
    1. Remove the bolt, 2 nuts, water by-pass pipe and gasket.
  13. REMOVE INLET WATER  (See REMOVAL )
  14. REMOVE THERMOSTAT  (See REMOVAL )
    Fig 5: Locating Water By-Pass Pipe Bolt And Nuts
    G05997956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the bolt and V-ribbed belt tensioner.
  16. REMOVE WATER PUMP ASSEMBLY  (See REMOVAL )
    Fig 6: Locating V-Ribbed Belt Tensioner Bolt
    G05998871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE WATER DRAIN COCK 
    1. Remove the water drain cock plug from the water drain cock.
    2. Remove the water drain cock from the cylinder block.
  18. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler)  (See INSPECTION )
    Fig 7: Locating Water Drain Cock
    G05997957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE INLET WATER HOUSING 
    1. Remove the 4 bolts, nut, inlet water housing and gasket.
    Fig 8: Locating Inlet Water Housing Bolts And Nut
    G05997958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE CRANKSHAFT PULLEY 
    1. Using SST, hold the crankshaft pulley and loosen the pulley bolt. Further loosen the bolt until 2 or 3 threads are screwed into the crankshaft.

      SST 09213-54015, 09330-00021, 91551 -80650 

      Fig 9: Loosening Crankshaft Pulley Bolts
      G06112223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and the pulley bolt, remove the crankshaft pulley.

      SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05011) 

      HINT:

      Apply a lubricant to the threads and end of SST.

      Fig 10: Removing Crankshaft Pulley Using SST And Pulley Bolt
      G05997960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 16 bolts, 3 seal washers, cylinder head cover and gasket.
      Fig 11: Locating Cylinder Head Cover Bolts And Seal Washers
      G05999043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 gaskets from the camshaft bearing caps.
    Fig 12: Locating Camshaft Bearing Caps Gaskets
    G05999044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE SPARK PLUG TUBE GASKET 
    1. Using a screwdriver, pry out the 4 plug tube gaskets.
    NOTE: Be careful not to damage the cylinder head cover.

    HINT:

    Tape the screwdriver tip before use.

    Fig 13: Prying Out Plug Tube Gaskets
    G05999045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE ENGINE MOUNTING BRACKET RH  (See REMOVAL )
  24. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY  (See REMOVAL )
  25. REMOVE TIMING CHAIN COVER TIGHT PLUG 
    1. Using a 14 mm hexagon wrench, remove the plug and gasket.
    Fig 14: Identifying Timing Chain Cover Tight Plug And Gasket
    G05997961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE TIMING CHAIN COVER PLATE 
    1. Remove the 4 bolts, timing chain cover plate and gasket.
  27. REMOVE TIMING CHAIN COVER OIL SEAL  (See REMOVAL )
  28. SET NO. 1 CYLINDER TO TDC/COMPRESSION  (See REMOVAL )
  29. REMOVE TIMING CHAIN GUIDE  (See INSTALLATION )
    Fig 15: Locating Timing Chain Cover Plate Bolts
    G05997962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY  (See INSTALLATION )
  31. REMOVE CHAIN TENSIONER SLIPPER  (See INSTALLATION )
  32. REMOVE CHAIN SUB-ASSEMBLY 
  33. REMOVE NO. 1 CHAIN VIBRATION DAMPER  (See INSTALLATION )
  34. REMOVE CRANKSHAFT TIMING SPROCKET 
    1. Remove the crankshaft timing sprocket from the crankshaft.
  35. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY  (See INSTALLATION )
  36. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY  (See INSTALLATION )
  37. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY  (See INSTALLATION )
    Fig 16: Identifying Crankshaft Timing Sprocket And Crankshaft
    G05997963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE CAMSHAFT BEARING CAP  (See INSTALLATION )
  39. REMOVE OIL CONTROL VALVE FILTER 
    1. Remove the oil control valve filter from the No. 1 camshaft bearing cap.
  40. REMOVE CAMSHAFT  (See INSTALLATION )
    Fig 17: Identifying Oil Control Valve Filter
    G05997964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE NO. 1 CAMSHAFT BEARING 
    1. Remove the No. 1 camshaft bearing.
    Fig 18: Identifying No. 1 Camshaft Bearing
    G05997965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE NO. 2 CAMSHAFT BEARING 
    1. Remove the No. 2 camshaft bearing.
  43. REMOVE CAMSHAFT HOUSING STUD BOLT 
    NOTE: If a stud bolt is deformed or its threads are damaged, replace it.
  44. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN 
    NOTE: It is not necessary to remove the ring pin unless it is being replaced.
    Fig 19: Identifying No. 2 Camshaft Bearing
    G05997966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE CAMSHAFT HOUSING STRAIGHT PIN 
    NOTE: It is not necessary to remove the straight pin unless it is being replaced.
  46. REMOVE VALVE ROCKER ARM SUB-ASSEMBLY  (See INSTALLATION )
  47. REMOVE VALVE LASH ADJUSTER ASSEMBLY  (See INSTALLATION )
  48. REMOVE VALVE STEM CAP  (See REMOVAL )
  49. REMOVE CYLINDER HEAD SUB-ASSEMBLY  (See REMOVAL )
  50. REMOVE CYLINDER HEAD GASKET  (See REMOVAL )
  51. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    1. Remove the cylinder block water jacket spacer from the cylinder block.
    NOTE: Be sure to remove the water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block is inverted.
  52. REMOVE OIL FILTER CAP ASSEMBLY  (See REPLACEMENT )
    Fig 20: Identifying Cylinder Block Water Jacket Spacer And Cylinder Block
    G05997967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Remove the 11 bolts and 2 nuts.
      Fig 21: Locating Oil Pan Sub-Assembly Bolts And Nuts
      G05997968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the blade of an oil pan seal cutter between the oil pan and stiffening crankcase, cut off the applied sealer and remove the oil pan.
    NOTE:
    • Be careful not to damage the stiffening crankcase contact surface of the oil pan.
    • Be careful not to damage the stiffening crankcase flange.
    Fig 22: Inserting Blade Of Oil Pan Seal Cutter Between Oil Pan And Stiffening Crankcase
    G05997969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the 3 bolts, oil strainer and gasket.
    Fig 23: Locating Oil Strainer Sub-Assembly Bolts
    G05997970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE NO. 1 OIL PAN BAFFLE PLATE 
    1. Remove the 5 bolts and oil pan baffle plate.
    Fig 24: Locating No. 1 Oil Pan Baffle Plate Bolts
    G05997971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSPECT CRANKSHAFT BACKLASH 
    1. Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.

      Standard backlash: 

      0.005 to 0.020 mm (0.000197 to 0.000787 in.) 

      Maximum backlash: 

      0.020 mm (0.000787 in.) 

      If the backlash is more than the maximum, replace the engine balancer assembly.

      Fig 25: Measuring Backlash Of Crankshaft And Balance Shaft
      G05997972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE ENGINE BALANCER ASSEMBLY 
    1. Remove the 7 bolts and engine balancer.
    NOTE: Do not disassemble the engine balancer.
  58. INSPECT BALANCE SHAFT THRUST CLEARANCE  (See REASSEMBLY )
    Fig 26: Locating Engine Balancer Assembly Bolts
    G05997973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE STIFFENING CRANKCASE ASSEMBLY 
    1. Remove the 7 bolts.
      Fig 27: Locating Stiffening Crankcase Assembly Bolts
      G05997974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the stiffening crankcase by prying between the stiffening crankcase and cylinder block at the places shown in the illustration.

      HINT:

      Tape the screwdriver tip before use.

      NOTE: Be careful not to damage the contact surfaces of the cylinder block and stiffening crankcase.
  60. REMOVE STIFFENING CRANKCASE STUD BOLT 
    NOTE: If a stud bolt is deformed or its threads are damaged, replace it.
  61. REMOVE STIFFENING CRANKCASE RING PIN 
    NOTE: It is not necessary to remove the ring pin unless it is being replaced.
    Fig 28: Locating Contact Surfaces Of Cylinder Block And Stiffening Crankcase
    G05997975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE REAR ENGINE OIL SEAL 
    1. Remove the rear engine oil seal from the cylinder block.
    Fig 29: Identifying Rear Engine Oil Seal
    G06112243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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