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Disassembly [10/2014 - ]: Procedure

  1. REMOVE ENGINE COVER JOINT 
    1. Remove the 3 engine cover joints.
      GTY508604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE SPARK PLUG 

    Refer to PROCEDURE - Step 3

  3. REMOVE KNOCK CONTROL SENSOR 

    Refer to PROCEDURE - Step 2

  4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 5

  5. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 1

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 2

  7. REMOVE CAMSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 2

  8. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
    1. Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.
  9. REMOVE OIL FILLER CAP GASKET 
    1. Remove the oil filler cap gasket from the oil filler cap sub-assembly.
  10. REMOVE CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  11. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 

    Refer to PROCEDURE - Step 2

  12. REMOVE VENTILATION CASE SUB-ASSEMBLY 
    1. Remove the 8 bolts and 2 nuts.
      GTY195361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the ventilation case sub-assembly by prying between the ventilation case sub-assembly and cylinder block sub-assembly with a screwdriver.
      GTY188620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the contact surfaces of the cylinder block sub-assembly and ventilation case sub-assembly.

      HINT: 

      Tape the screwdriver tip before use.

  13. REMOVE SEPARATOR CASE 
    1. Remove the 2 bolts, separator case and gasket.
      GTY430039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE CRANKSHAFT PULLEY 
    1. Using SST, hold the crankshaft pulley and loosen the pulley bolt. Further loosen the pulley bolt until 2 or 3 threads are screwed into the crankshaft.
      GTY546013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
      • SST: 09213-54015 
      • SST: 09330-00021 
      • SST: 91551-80650 
    2. Using SST and the pulley bolt, remove the crankshaft pulley.
      GTY590887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Pulley Bolt
      *a Hold
      *b Turn
      • SST: 09950-50013 
        1. 09951-05010
        2. 09952-05010
        3. 09953-05020
        4. 09954-05011

      HINT: 

      Apply a lubricant to the threads and end of SST.

  15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.
      GTY316230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 camshaft bearing cap oil hole gaskets.
      GTY508605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE STUD BOLT 
    NOTE:

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

    1. Using an E6 "TORX" socket wrench, remove the 3 stud bolts from the cylinder head cover sub-assembly.
      GTY322891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE SPARK PLUG TUBE GASKET 
    1. Using a screwdriver, pry out the 4 spark plug tube gaskets.
      GTY323189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Tape
      NOTE:

      Be careful not to damage the cylinder head cover sub-assembly.

      HINT: 

      Tape the screwdriver tip before use.

  18. REMOVE ENGINE MOUNTING BRACKET RH 

    Refer to PROCEDURE - Step 6

  19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  20. REMOVE OIL PUMP RELIEF VALVE PLUG 
    1. Using a 14 mm hexagon wrench, remove the oil pump relief valve plug and gasket.
      GTY312189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TIMING CHAIN COVER PLATE 
    1. Remove the 4 bolts, timing chain cover plate and gasket.
      GTY312183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE TIMING CHAIN COVER OIL SEAL 

    Refer to PROCEDURE - Step 8

  23. SET NO. 1 CYLINDER TO TDC/COMPRESSION 

    See step  14

  24. REMOVE TIMING CHAIN GUIDE 

    See step  15

  25. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 

    See step  16

  26. REMOVE CHAIN TENSIONER SLIPPER 

    See step  17

  27. REMOVE CHAIN SUB-ASSEMBLY 
    1. Remove the chain sub-assembly.
  28. REMOVE NO. 1 CHAIN VIBRATION DAMPER 

    See step  19

  29. REMOVE CRANKSHAFT TIMING SPROCKET 
    1. Remove the crankshaft timing sprocket from the crankshaft.
      GTY314227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 

    See step  20

  31. REMOVE CAMSHAFT TIMING SPROCKET 

    See step  21

  32. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY 

    See step  22

  33. REMOVE CAMSHAFT BEARING CAP 

    See step  23

  34. REMOVE OIL CONTROL VALVE FILTER 
    1. Remove the oil control valve filter from the No. 1 camshaft bearing cap.
      GTY384553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE CAMSHAFT 

    See step  26

  36. REMOVE NO. 1 CAMSHAFT BEARING 
    1. Remove the No. 1 camshaft bearing from the No. 1 camshaft bearing cap.
      GTY195088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE NO. 2 CAMSHAFT BEARING 
    1. Remove the No. 2 camshaft bearing from the camshaft housing sub-assembly.
      GTY195089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE STUD BOLT 
    NOTE:

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

    1. Using an E8 "TORX" socket wrench, remove the stud bolt from the camshaft housing sub-assembly.
      GTY316356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN 
    NOTE:

    It is not necessary to remove the ring pin unless it is being replaced.

    1. Remove the 10 camshaft bearing cap setting ring pins from the camshaft housing sub-assembly.
      GTY316357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE STRAIGHT PIN 
    NOTE:

    It is not necessary to remove the straight pin unless it is being replaced.

    1. Remove the 2 straight pins from the camshaft housing sub-assembly.
      GTY322233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 

    See step  28

  42. REMOVE VALVE LASH ADJUSTER ASSEMBLY 

    See step  29

  43. REMOVE VALVE STEM CAP 

    See step  30

  44. REMOVE CYLINDER HEAD SUB-ASSEMBLY 

    See step  31

  45. REMOVE CYLINDER HEAD GASKET 

    See step  32

  46. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    1. Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.
      GTY312332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be sure to remove the cylinder block water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block sub-assembly is inverted.

  47. REMOVE OIL FILTER CAP ASSEMBLY 

    Refer to PROCEDURE - Step 2

  48. REMOVE OIL PAN DRAIN PLUG 
    1. Remove the oil pan drain plug and gasket from the oil pan sub-assembly.
  49. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Remove the 11 bolts and 2 nuts.
      GTY588531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Nut
    2. Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut off the applied sealer and remove the oil pan sub-assembly.
      GTY192227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to damage the stiffening crankcase assembly contact surface of the oil pan sub-assembly.
      • Be careful not to damage the stiffening crankcase flange.
  50. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the 3 bolts, oil strainer sub-assembly and gasket.
      GTY184315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE NO. 1 OIL PAN BAFFLE PLATE 
    1. Remove the 5 bolts and No. 1 oil pan baffle plate.
      GTY190555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSPECT CRANKSHAFT BACKLASH 
    1. Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.
      GTY184440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Backlash

      0.05 to 0.20 mm (0.00197 to 0.00787 in.)

      Maximum Backlash

      0.20 mm (0.00787 in.)

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

  53. REMOVE ENGINE BALANCER ASSEMBLY 
    1. Remove the 7 bolts and engine balancer assembly.
      GTY195093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not disassemble the engine balancer assembly.

  54. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE 

    See step  14

  55. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE 

    See step  15

  56. REMOVE STIFFENING CRANKCASE ASSEMBLY 
    1. Remove the 7 bolts.
      GTY195095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly at the places shown in the illustration.
      GTY303021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a LH Side
      *b RH Side
      NOTE:

      Be careful not to damage the contact surfaces of the cylinder block sub-assembly and stiffening crankcase assembly.

      HINT: 

      Tape the screwdriver tip before use.

  57. REMOVE STUD BOLT 
    NOTE:

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

    1. Using an E5 and E8 "TORX" socket wrench, remove the 3 stud bolts from the stiffening crankcase assembly.
      GTY322228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE RING PIN 
    NOTE:

    It is not necessary to remove the ring pin unless it is being replaced.

    1. Remove the 2 ring pins from the stiffening crankcase assembly.
      GTY316335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE REAR ENGINE OIL SEAL 
    1. Remove the rear engine oil seal from the cylinder block sub-assembly.
      GTY195097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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