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Engine Unit: Disassembly

  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
    1. Remove the oil filler cap from the cylinder head cover.
    Fig 1: Locating Oil Filler Cap
    G04974252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE OIL FILLER CAP GASKET 
    1. Remove the oil filler cap gasket from the oil filler cap.
    Fig 2: Locating Oil Filler Cap Gasket
    G04974253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE VENTILATION VALVE SUB-ASSEMBLY 
    1. Using a 22 mm deep socket wrench, remove the ventilation valve from the cylinder head cover.
  4. REMOVE SPARK PLUG  (See REMOVAL )
  5. REMOVE OIL FILTER SUB-ASSEMBLY  (See REPLACEMENT )
    Fig 3: Locating Ventilation Valve
    G04974254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE OIL FILTER UNION 
    1. Using a 12 mm socket hexagon wrench, remove the oil filter union.
    Fig 4: Locating Oil Filter Union
    G04974399Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 8 bolts and 2 nuts, and remove the cylinder head cover.
    Fig 5: Locating Cylinder Head Cover Bolts And Nuts
    G05387369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE CYLINDER HEAD COVER GASKET 
    1. Remove the cylinder head cover gasket from the cylinder head cover.
  9. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY  (See REMOVAL )
    Fig 6: Locating Cylinder Head Cover Gasket
    G04974398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE CRANKSHAFT POSITION SENSOR 
    1. Remove the wire harness clamp.
    2. Separate the wire harness from the wire harness clamp bracket.
      Fig 7: Locating Crankshaft Position Sensor
      G04974260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and sensor.
    Fig 8: Locating Crankshaft Position Sensor And Bolts
    G04974261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE CAMSHAFT POSITION SENSOR 
    1. Remove the bolt and camshaft position sensor.
  12. SET NO. 1 CYLINDER TO TDC/COMPRESSION  (See REMOVAL )
  13. REMOVE CRANKSHAFT PULLEY  (See REMOVAL )
    Fig 9: Locating Camshaft Position Sensor And Bolts
    G04974262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
    1. Remove the bolt and camshaft timing oil control valve from the cylinder head.
      NOTE: The camshaft timing oil control valve may be damaged when loosening the cylinder head bolts if the oil control valve is not removed.
    2. Remove the O-ring from the camshaft timing oil control valve.
    Fig 10: Locating Camshaft Timing Oil Control Valve
    G04974382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY  (See REMOVAL )
  16. REMOVE WATER PUMP PULLEY  (See REMOVAL )
  17. REMOVE WATER PUMP ASSEMBLY  (See REMOVAL )
  18. REMOVE OIL PAN DRAIN PLUG 
    1. Remove the oil pan drain plug from the oil pan.
    Fig 11: Locating Oil Pan Drain Plug
    G04974263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Remove the 12 bolts and 2 nuts.
      Fig 12: Locating Oil Pan Bolts And Nuts
      G05387375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the blade of an oil pan seal cutter between the crankcase, chain cover and oil pan, then cut through the applied sealer and remove the oil pan.
      NOTE: Be careful not to damage the contact surfaces of the crankcase, chain cover and oil pan.
      Fig 13: Removing Oil Pan Seal With Cutter
      G05387376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY  (See REMOVAL )
  21. REMOVE FRONT CRANKSHAFT OIL SEAL  (See REMOVAL )
  22. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE  (See REMOVAL )
  23. REMOVE TIMING CHAIN GUIDE  (See REMOVAL )
  24. REMOVE CHAIN TENSIONER SLIPPER  (See REMOVAL )
  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER  (See REMOVAL )
  26. REMOVE CHAIN SUB-ASSEMBLY 
  27. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET  (See REMOVAL )
  28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY  (See REMOVAL )
  29. REMOVE KEYS 
    1. Remove the 2 pulley set keys from the crankshaft.
    Fig 14: Identifying Pulley Set Keys
    G04974265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE NO. 2 CAMSHAFT 
    1. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
      NOTE: Uniformly loosen the bolts while keeping the camshaft level.

      HINT:

      Arrange the removed parts in the correct order.

    2. Remove the 5 bearing caps.
    3. Remove the No. 2 camshaft.
    Fig 15: Identifying No. 2 Camshaft Bearing Cap Bolts Removing Sequence
    G04974008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE CAMSHAFT 
    1. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
      NOTE: Uniformly loosen the bolts while keeping the camshaft level.

      HINT:

      Arrange the removed parts in the correct order.

    2. Remove the 5 bearing caps.
    3. Remove the camshaft.
    Fig 16: Identifying Camshaft Bearing Cap Bolts Removing Sequence
    G04974010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE NO. 1 CAMSHAFT BEARING 
    1. Remove the camshaft bearing from the No. 1 camshaft bearing cap.
    Fig 17: Identifying No. 1 Camshaft Bearing Cap And Bearing
    G04974268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE NO. 2 CAMSHAFT BEARING 
    1. Remove the No. 2 camshaft bearing from the cylinder head.
    Fig 18: Identifying No. 2 Camshaft Bearing
    G04974269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET 
    1. Clamp the camshaft in a vise.
      NOTE:
      • Do not overtighten the vise.
      • Do not damage the camshaft.
      Fig 19: Removing/Installing Camshaft Timing Gear With Vise
      G04828951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and camshaft timing gear or sprocket.
  35. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY  (See REMOVAL )
  36. REMOVE CYLINDER HEAD SUB-ASSEMBLY  (See REMOVAL )
  37. REMOVE CYLINDER HEAD GASKET 
    Fig 20: Identifying Cylinder Head Gasket
    G05129039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    1. Using needle nose pliers, remove the cylinder block water jacket spacer from the water jacket.
      NOTE: Before turning the cylinder block upside down, make sure that the water jacket spacer is removed, as it will fall out.
      Fig 21: Removing Cylinder Block Water Jacket Spacer
      G04974271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. Remove the water drain cock from the stiffening crankcase.
    2. Remove the water drain cock plug from the water drain cock.
    Fig 22: Identifying Water Drain Cock
    G04974272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE OIL CONTROL VALVE FILTER 
    1. Using an 8 mm socket hexagon wrench, remove the plug, gasket and oil control valve filter.
    Fig 23: Identifying Plug, Gasket And Oil Control Valve Filter
    G04974377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE NO. 1 TAPER HEAD SCREW PLUG 
    1. Remove the No. 1 taper head screw plug.
      Fig 24: Identifying No. 1 Taper Head Screw Plug
      G05387389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE OIL PUMP ASSEMBLY  (See DISASSEMBLY )
  43. INSPECT BALANCESHAFT THRUST CLEARANCE  (See INSPECTION )
  44. INSPECT BALANCESHAFT OIL CLEARANCE  (See INSPECTION )
  45. REMOVE NO. 1 AND NO. 2 BALANCESHAFTS 
    1. Remove the No. 1 and No. 2 balanceshafts.
    Fig 25: Locating No. 1 And No. 2 Balanceshafts
    G05387390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE NO. 1 BALANCESHAFT BEARING 
    1. Remove the 8 No. 1 balanceshaft bearings shown in the illustration.
  47. REMOVE REAR CRANKSHAFT OIL SEAL  (See REMOVAL  )
    Fig 26: Removing/Installing No. 1 Balanceshaft Bearings
    G06041143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE STIFFENING CRANKCASE ASSEMBLY 
    1. Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.
      Fig 27: Identifying Stiffening Crankcase Bolts Removing Sequence
      G05387392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver with its tip wrapped with protective tape, remove the crankcase by prying between the crankcase and cylinder block.
      NOTE: Be careful not to damage the contact surfaces between the crankcase and cylinder block.
      Fig 28: Prying Between Crankcase And Cylinder Block
      G05387393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring from the cylinder block.
      Fig 29: Identifying O-Ring
      G04974282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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