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Removal [08/2020 - ]: Procedure

  1. INSTALL ENGINE TO ENGINE STAND 

    Refer to PROCEDURE - Step 55 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 55 [12/2021 - ]

  2. REMOVE ENGINE HANGER 

    Refer to PROCEDURE - Step 56 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 56 [12/2021 - ]

  3. REMOVE THROTTLE BODY ASSEMBLY 

    Refer to PROCEDURE - Step 4 [10/2017 - 12/2021] , or refer to PROCEDURE - Step 4 [12/2021 - ]

  4. REMOVE THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 5 [10/2017 - 12/2021] , or refer to PROCEDURE - Step 5 [12/2021 - ]

  5. REMOVE PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 8 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 7 [12/2021 - ]

  6. DISCONNECT VENTILATION HOSE 

    Refer to PROCEDURE - Step 5 [10/2017 - 12/2021] , or refer to PROCEDURE - Step 5 [12/2021 - ]

  7. REMOVE INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 6 [10/2017 - 12/2021] , or refer to PROCEDURE - Step 6 [12/2021 - ]

  8. REMOVE WIRE HARNESS CLAMP BRACKET 

    Refer to PROCEDURE - Step 11 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 10 [12/2021 - ]

  9. DISCONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 12 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 11 [12/2021 - ]

  10. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 15 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 14 [12/2021 - ]

  11. REMOVE NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 16 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 15 [12/2021 - ]

  12. REMOVE INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 17 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 16 [12/2021 - ]

  13. REMOVE FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 18 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 17 [12/2021 - ]

  14. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 9

  15. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 7 [12/2017 - 12/2021] , or refer to PROCEDURE - Step 7 [12/2021 - ]

  16. REMOVE MANIFOLD STAY 

    Refer to PROCEDURE - Step 8 [12/2017 - 12/2021] , or refer to PROCEDURE - Step 8 [12/2021 - ]

  17. REMOVE EXHAUST MANIFOLD 

    Refer to PROCEDURE - Step 9 [12/2017 - 12/2021] , or refer to PROCEDURE - Step 9 [12/2021 - ]

  18. REMOVE VENTILATION HOSE 

    Refer to PROCEDURE - Step 17

  19. DISCONNECT NO. 3 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 15

  20. REMOVE WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 19

  21. REMOVE WATER INLET HOSE 

    Refer to PROCEDURE - Step 20

  22. REMOVE WATER INLET 

    Refer to PROCEDURE - Step 3

  23. REMOVE THERMOSTAT 

    Refer to PROCEDURE - Step 4

  24. REMOVE IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2 [10/2017 - 12/2021] , or refer to PROCEDURE - Step 2 [12/2021 - ]

  25. REMOVE VACUUM PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 4

  26. REMOVE NO. 1 VACUUM PUMP BRACKET 

    Refer to PROCEDURE - Step 24

  27. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 26

  28. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 12

  29. REMOVE CYLINDER HEAD COVER GASKET 

    Refer to PROCEDURE - Step 13

  30. SET NO. 1 CYLINDER TO TDC/COMPRESSION 

    Refer to PROCEDURE - Step 18

  31. REMOVE CRANKSHAFT PULLEY 

    Refer to PROCEDURE - Step 6

  32. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 20

  33. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Remove the 3 bolts and engine mounting bracket RH from the timing chain cover sub-assembly.
      GTY765101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts and oil filter bracket from the timing chain cover sub-assembly.
      GTY420343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 O-rings from the timing chain cover sub-assembly.
      GTY433986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 19 bolts and seal washer from the timing chain cover sub-assembly.
      GTY495213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Washer
    5. Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly with a screwdriver as shown in the illustration.
      GTY492239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

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

      HINT: 

      Tape the screwdriver tip before use.

    6. Remove the O-ring from the cylinder block sub-assembly.
      GTY447514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 2 O-rings from the cylinder head sub-assembly.
    8. Remove the 3 bolts and engine water pump assembly from the timing chain cover sub-assembly.
      GTY438133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the gasket from the timing chain cover sub-assembly.
      GTY438176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE TIMING CHAIN COVER OIL SEAL 
    1. Place the timing chain cover sub-assembly on wooden blocks.
      GTY760257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      *b Wooden Block
    2. Using a screwdriver, tap out the timing chain cover oil seal.
      NOTE:

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

      HINT: 

      Tape the screwdriver tip before use.

  35. REMOVE CHAIN TENSIONER SLIPPER 

    Refer to PROCEDURE - Step 25

  36. REMOVE NO. 1 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 26

  37. REMOVE CHAIN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 27

  38. REMOVE CRANKSHAFT TIMING SPROCKET 
    1. Remove the crankshaft timing sprocket.
      GTY449126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE NO. 2 CHAIN SUB-ASSEMBLY 
    1. Temporarily install the crankshaft pulley with the crankshaft pulley bolt.
      GTY772296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, hold the crankshaft pulley. Then remove the oil pump drive shaft gear nut.
      • SST: 09213-5401509330-00021 

      HINT: 

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-00850 (quantity: 2)

    3. Remove SST, the crankshaft pulley bolt and crankshaft pulley.
    4. Remove the bolt, chain tensioner plate and chain damper spring.
      GTY764307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Chain Damper Spring
      *2 Chain Tensioner Plate
    5. Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain sub-assembly.
      GTY453929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Chain Sub-assembly
      *2 Oil Pump Drive Gear
      *3 Oil Pump Drive Shaft Gear
  40. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Remove the 10 bolts and 2 nuts.
      GTY327135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the blade of an oil pan seal cutter between the stiffening crankcase assembly and No. 2 oil pan sub-assembly. Cut through the sealer and remove the No. 2 oil pan sub-assembly.
      GTY145991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to damage the surface of the No. 2 oil pan sub-assembly which contacts the stiffening crankcase assembly.
      • Be careful not to damage the stiffening crankcase assembly flange.
  41. REMOVE OIL PUMP ASSEMBLY 
    1. Remove the 3 bolts and oil pump assembly from the stiffening crankcase assembly.
      GTY451012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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