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Removal [08/2015 - ]: Procedure

  1. REMOVE ENGINE ASSEMBLY 

    (Refer to REMOVAL [08/2015 - ] )

  2. REMOVE NO. 1 EMISSION CONTROL VALVE SET 

    Refer to PROCEDURE - Step 3

  3. REMOVE NO. 2 EMISSION CONTROL VALVE SET 

    Refer to PROCEDURE - Step 4

  4. REMOVE IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 5

  5. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Remove the engine oil level dipstick.
      GTY177588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and engine oil level dipstick guide.
    3. Remove the O-ring from the engine oil level dipstick guide.
  6. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. Disconnect the 2 hoses.
      GTY227723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and water by-pass pipe sub-assembly.
  7. REMOVE WATER INLET HOUSING 
    1. Disconnect the 3 water by-pass hoses.
      GTY178793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts and water inlet housing.
      GTY182761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring and gasket from the water outlet pipe and water pump assembly.
      GTY182297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 3 water by-pass hoses.
      GTY178791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY 
    1. Remove the bolt and No. 1 idler pulley sub-assembly.
      GTY171380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 17

  10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the 5 bolts and V-ribbed belt tensioner assembly.
      GTY188931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE OIL FILTER BRACKET 
    1. Remove the 2 nuts, bolt, oil filter bracket and gasket.
      GTY222617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE CRANKSHAFT PULLEY 
    1. Using SST, hold the crankshaft pulley and loosen the pulley bolt. Continue to loosen the bolt until only 2 or 3 threads are screwed into the crankshaft.
      GTY698770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09213-54015 
        1. 91651-60855
      • SST: 09330-00021 
    2. Using the pulley set bolt and SST, remove the crankshaft pulley and pulley bolt.
      GTY719544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-50013 
        1. 09951-05010
        2. 09952-05010
        3. 09953-05020
        4. 09954-05031
  13. REMOVE NO. 1 OIL PIPE 
    1. Remove the 2 oil pipe unions, oil control valve filter LH, 3 gaskets and No. 1 oil pipe.
      GTY181687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not touch the mesh when removing the oil control valve filter.

  14. REMOVE NO. 2 OIL PIPE 
    1. Remove the 2 oil pipe unions, oil control valve filter RH, 3 gaskets and No. 2 oil pipe.
      GTY181686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not touch the mesh when removing the oil control valve filter.

  15. REMOVE REAR CYLINDER HEAD COVER 

    Refer to PROCEDURE - Step 2

  16. DISCONNECT FUEL PIPE SUB-ASSEMBLY 
    1. Remove the 2 bolts and disconnect the fuel pipe sub-assembly.
  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Remove the 12 bolts, seal washer, cylinder head cover sub-assembly LH and gasket.
      GTY181700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Make sure the removed parts are returned to the same places they were removed from.

    2. Remove the 3 gaskets.
      GTY722663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and gasket.
      GTY181699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Make sure the removed parts are returned to the same places they were removed from.

    2. Remove the 3 gaskets.
      GTY181698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Remove the 10 bolts and 2 nuts.
      GTY167471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Make sure the removed parts are returned to the same places they were removed from.

    2. Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.
      GTY180513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Oil Pan Seal Cutter
      NOTE:

      Be careful not to damage the contact surfaces of the oil pans.

  20. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the 2 nuts, oil strainer sub-assembly and gasket.
      GTY173027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Remove the 17 bolts and 2 nuts.
      GTY177570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Make sure the removed parts are returned to the same places they were removed from.

    2. Using a screwdriver, remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block as shown in the illustration.
      GTY215941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 LH Side
      *2 RH Side
      *a Pry

      HINT: 

      Tape the screwdriver tip before use.

      NOTE:

      Be careful not to damage the contact surfaces of the cylinder block and oil pan.

    3. Remove the 3 O-rings from the timing chain cover sub-assembly.
      GTY177615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Remove the 26 bolts and the 2 nuts.
      GTY187821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head or cylinder block with a screwdriver.
      GTY187819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Tape the screwdriver tip before use.

      NOTE:

      Be careful not to damage the contact surfaces of the timing chain cover sub-assembly, cylinder block and cylinder head.

    3. Remove the oil pump gasket from the cylinder block.
      GTY180900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FRONT CRANKSHAFT OIL SEAL 
    1. Using a screwdriver and wooden block, pry out the front crankshaft oil seal.

      HINT: 

      Tape the screwdriver tip before use.

      NOTE:

      Do not damage the surface of the oil seal press fit hole.

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