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Disassembly [12/2015 - 08/2016]: Procedure

WARNING: This page is about a different car, the 2016 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
    1. Remove the oil filler cap sub-assembly and oil filler gasket.
  2. REMOVE SPARK PLUG 

    Refer to PROCEDURE - Step 4

  3. REMOVE OIL PAN DRAIN PLUG 
    1. Remove the oil pan drain plug and oil pan drain plug gasket.
      GTY232260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE VENTILATION VALVE SUB-ASSEMBLY 
    1. Remove the ventilation valve sub-assembly.
      GTY439178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE VVT SENSOR 

    (Refer to REMOVAL [12/2015 - 08/2016] )

  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 

    (Refer to REMOVAL [12/2015 - 08/2016] )

  7. REMOVE CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 2

  8. REMOVE NO. 1 OIL PIPE 
    1. Remove the 2 oil pipe unions, gaskets and No. 1 oil pipe.
      GTY706845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Oil Pipe Union
    2. Remove the oil control valve filter LH and gaskets.
  9. REMOVE OIL PIPE 
    1. Remove the bolt.
      GTY740187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Oil Pipe Union
      *2 Bolt
    2. Remove the 2 oil pipe unions and oil pipe.
    3. Remove the oil control valve filter RH and gaskets.
  10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    GTY299254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    TEXT IN ILLUSTRATION

    *a for Bank 1
    *b for Bank 2
    1. Remove the 2 cylinder block water drain cock sub-assemblies from the cylinder block.
    2. Remove the 2 cylinder block water drain cock plugs from the 2 water drain cock sub-assemblies.
  11. REMOVE OIL FILTER ELEMENT 

    Refer to PROCEDURE - Step 2

  12. REMOVE CRANKSHAFT PULLEY 

    See step  4

  13. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler) 
    1. Remove the bolt, 2 clamps and 4 clips, and disconnect the 2 water by-pass hoses.
      GTY695893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Clip
      *2 Clamp
      *3 Bolt
    2. Remove the union bolt, oil cooler assembly, and O-ring.
      GTY383449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) 
    1. Remove the 3 bolts, 3 nuts, and oil cooler pipe with the No. 1 oil cooler bracket.
      GTY469497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, 2 nuts, No. 1 oil cooler bracket, and gasket.
      GTY697927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Nut
      *2 Bolt
    3. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
  15. REMOVE ENGINE OIL DIPSTICK GUIDE (w/ Oil Cooler) 
    1. Remove the engine oil dipstick guide.
      GTY699024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring.
      GTY452297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE ENGINE OIL DIPSTICK GUIDE (w/o Oil Cooler) 
    1. Remove the bolt and engine oil dipstick guide.
      GTY446805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring.
      GTY452297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH 
    1. Remove the 6 bolts and No. 1 front engine mounting bracket LH.
      GTY124023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
  18. REMOVE WATER INLET HOUSING 
    1. Remove the 2 nuts, water inlet and thermostat.
      GTY439183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket.
    3. Remove the 2 stud bolts.
    4. Separate the No. 1 water by-pass hose from the water inlet housing.
    5. Remove the drain cock plug.
      GTY690705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Nut
      *2 Bolt
    6. Remove the drain cock assembly.
    7. Remove the 2 bolts, nut, and water inlet housing.
    8. Remove the 2 O-rings.
      GTY146501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE WATER OUTLET 
    1. Remove the 2 bolts, 4 nuts and water outlet.
      GTY726415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Nut
      *2 Bolt
    2. Remove the 2 gaskets and O-ring.
      GTY295919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.
      GTY146504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 gaskets.
      GTY439216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Remove the 12 bolts, seal washer, cylinder head cover sub-assembly LH and cylinder head cover gasket.
      GTY711990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Baffle Plate
      NOTE:

      The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the cylinder head cover sub-assembly LH.

    2. Remove the 3 gaskets.
      GTY439262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Remove the 16 bolts and 2 nuts.
      GTY711952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Nut
    2. Insert the blade of the oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.
      GTY145991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    3. Using an E6 "TORX" socket wrench, remove the 2 stud bolts.
  23. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.
      GTY728383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Bolt
      *2 Nut
    2. Using an E6 "TORX" socket wrench, remove the 2 stud bolts.
  24. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Remove the 16 bolts and 2 nuts.
      GTY709602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Nut
      *a w/o Oil Cooler
      *b w/ Oil Cooler

      HINT: 

      Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

    2. Remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly with a screwdriver.
      GTY738732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Protective Tape
      NOTE:

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

      HINT: 

      Tape the screwdriver tip before use.

    3. Remove the 2 O-rings.
      GTY295914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using an E8 "TORX" socket wrench, remove the 4 stud bolts.
  25. REMOVE NO. 1 OIL PAN BAFFLE PLATE 
    1. Remove the 7 bolts and No. 1 oil pan baffle plate.
      GTY146508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE ENGINE REAR OIL SEAL RETAINER 
    1. Remove the 6 bolts.
      GTY124017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, pry out the engine rear oil seal retainer.
      GTY698720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Protective Tape
      Pry
      NOTE:

      Be careful not to damage the engine rear oil seal retainer.

      HINT: 

      Tape the screwdriver tip before use.

  27. REMOVE ENGINE REAR OIL SEAL 
    1. Place the engine rear oil seal retainer on wooden blocks.
      GTY304179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Protective Tape
      *2 Wooden Block

      HINT: 

      Tape the screwdriver tip before use.

    2. Using a screwdriver and a hammer, tap out the oil seal.
      NOTE:

      Be careful not to damage the engine rear oil seal retainer.

      HINT: 

      Tape the screwdriver tip before use.

  28. REMOVE WATER PUMP ASSEMBLY 
    1. Remove the 16 bolts, water pump assembly and water pump gasket.
      GTY146512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Remove the 15 bolts and 2 nuts as shown in the illustration.
      GTY296682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Nut
    2. Remove the timing chain cover sub-assembly by prying between the timing chain cover and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver.
      GTY318931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Protective Tape
      NOTE:

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

      HINT: 

      Tape the screwdriver tip before use.

    3. Remove the 4 bolts, chain cover plate and chain cover plate gasket.
    4. Remove the gasket.
      GTY307825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE TIMING CHAIN CASE OIL SEAL 
    1. Using a screwdriver, pry out the timing chain case oil seal.
      GTY302398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Protective Tape
      *2 Wooden Block

      HINT: 

      Tape the screwdriver tip before use.

  31. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Temporarily tighten the pulley set bolt.
    2. Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression).
      GTY702405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Sensor Plate
      *a Center Line
      *b Timing Mark
    3. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.
      TEXT IN ILLUSTRATION

      *a Timing Mark

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

      GTY720214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
      GTY714319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Plunger
      *2 Stopper Plate
      *3 Pin
    2. Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm diameter (0.0500 in.) into the stopper plate hole.
    3. Remove the 2 bolts and No. 1 chain tensioner assembly.
      GTY450128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE CHAIN TENSIONER SLIPPER 
    1. Remove the chain tensioner slipper.
  34. REMOVE CHAIN SUB-ASSEMBLY 
    1. Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket.
      GTY720105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Sensor Plate
      *a Center Line
      *b Timing Mark
    2. Remove the pulley set bolt.
    3. Remove the chain sub-assembly from the crankshaft timing sprocket and place it on the crankshaft.
      GTY301808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks.
      GTY724781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a for Bank 1
    5. Remove the chain sub-assembly.
  35. REMOVE IDLE SPROCKET ASSEMBLY 
    1. Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft.
      GTY146516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE NO. 1 CHAIN VIBRATION DAMPER 
    1. Remove the 2 bolts and No. 1 chain vibration damper.
      GTY124072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE NO. 2 CHAIN VIBRATION DAMPER 
    1. Remove the 2 No. 2 chain vibration dampers.
  38. REMOVE CRANKSHAFT TIMING SPROCKET 
    1. Remove the crankshaft timing sprocket from the crankshaft.
      GTY191932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 keys from the crankshaft.
  39. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) 

    See step  32

  40. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY 

    See step  33

  41. REMOVE CAMSHAFT BEARING CAP (for Bank 1) 

    See step  34

  42. REMOVE CAMSHAFT 

    See step  35

  43. REMOVE NO. 2 CAMSHAFT 

    See step  36

  44. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH 

    See step  37

  45. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) 

    See step  38

  46. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY 

    See step  39

  47. REMOVE CAMSHAFT BEARING CAP (for Bank 2) 

    See step  40

  48. REMOVE NO. 3 CAMSHAFT 

    See step  41

  49. REMOVE NO. 4 CAMSHAFT 

    See step  42

  50. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH 

    See step  43

  51. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 

    See step  2

  52. REMOVE VALVE LASH ADJUSTER ASSEMBLY 

    See step  3

  53. REMOVE VALVE STEM CAP 

    See step  4

  54. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH 

    See step  6

  55. REMOVE CYLINDER HEAD GASKET RH 

    See step  7

  56. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH 

    See step  8

  57. REMOVE CYLINDER HEAD GASKET LH 

    See step  9

  58. REMOVE WATER INLET PIPE 
    1. Remove 2 clamps and separate the No. 1 water by-pass hose.
    2. Remove the 2 bolts and water inlet pipe.
      GTY713425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a w/o Oil Cooler
      *b w/ Oil Cooler
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