Disassembly [11/2022 - ]: Procedure

Refer to PROCEDURE - Step 3

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Refer to PROCEDURE - Step 2

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Crankshaft Pulley Bolt	-	-
   *a	Hold	*b	Turn

   1. Using SST, hold the crankshaft pulley assembly and loosen the crankshaft pulley bolt. Further loosen the crankshaft pulley bolt until 2 or 3 threads remain screwed into the crankshaft.
      • SST: 09213-54015 
      • SST: 09330-00021 
   2. Using SST and the crankshaft pulley bolt, remove the crankshaft pulley assembly and crankshaft pulley bolt.
      • SST: 09950-50013 
        1. 09951-05010
        2. 09952-05010
        3. 09953-05020
        4. 09954-05070
        5. 09957-04010

      HINT: 

      Apply lubricant to the threads and end of SST.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using an 8 mm socket wrench, remove the 3 bolts, water by-pass outlet and water pipe outlet gasket from the cylinder head sub-assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using an 8 mm socket wrench, remove the 4 bolts (A).
   2. Remove the 12 bolts (B) and cylinder head cover sub-assembly from the camshaft housing sub-assembly.
   3. Remove the 7 cylinder head cover gaskets from the cylinder head cover sub-assembly.
   4. Remove the camshaft bearing cap oil hole gasket from the No. 1 camshaft bearing cap.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using a screwdriver, pry out the 4 spark plug tube gaskets from the cylinder head cover sub-assembly.
      NOTE:

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

      HINT: 

      Tape the screwdriver tip before use.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using a 10 mm hexagon wrench, remove the straight screw plug from the No. 2 timing chain cover assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the 20 bolts.

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the No. 2 timing chain cover assembly from the timing chain cover assembly by prying the No. 2 timing chain cover assembly with a screwdriver with its tip wrapped with protective tape.
      NOTE:

      Be careful not to damage the contact surfaces of the No. 2 timing chain cover assembly and timing chain cover assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Wooden Block

   -

   -

   1. Using a screwdriver and wooden block, pry 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.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Crankshaft Timing Gear Key	-	-
   *a	Approximately 4.63°	*b	Approximately 33.07°
   *c	Approximately 2.73°	*d	Timing Mark

   1. Temporarily install the crankshaft pulley bolt.
   2. Rotate the crankshaft clockwise and align the crankshaft timing gear key as shown in the illustration.
   3. Check that the timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.
   4. Remove the crankshaft pulley bolt.

      HINT: 

      As the exhaust camshaft sub-assembly may rotate counterclockwise strongly when the crankshaft pulley bolt is removed, use a wrench to hold the hexagonal portion of the exhaust camshaft sub-assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Chain Tensioner Plate	*2	Chain Damper Spring
   *3	Oil Pump Drive Chain Sub-assembly	*4	Oil Pump Drive Sprocket
   *5	Oil Pump Drive Shaft Sprocket	-	-
   *a	Bolt	-	-

   1. Temporarily install the crankshaft pulley assembly with the crankshaft pulley bolt.
   2. While holding the crankshaft pulley assembly with SST, remove the bolt.
      • SST: 09213-54015 
      • SST: 09330-00021 
   3. Remove SST, the crankshaft pulley bolt and crankshaft pulley assembly.
   4. Remove the chain tensioner plate and chain damper spring.
   5. Remove the oil pump drive sprocket, oil pump drive shaft sprocket and oil pump drive chain sub-assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Loosen	*b	Hold
   	Turn	-	-

   1. Hold the hexagonal portion of the exhaust camshaft sub-assembly with a wrench and turn the camshaft timing gear assembly clockwise to loosen the chain sub-assembly between the camshaft timing exhaust gear assembly and camshaft timing gear assembly.
   2. Using a wrench, hold the hexagonal portion of the intake camshaft sub-assembly.
      NOTE:

      • Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube with the wrench.
      • Do not disassemble the camshaft timing gear assembly.
   3. Using a 10 mm bi-hexagonal wrench, remove the bolt and camshaft timing gear assembly from the intake camshaft sub-assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Tape

   -

   -

   1. Using an 8 mm socket wrench, remove the bolt.
   2. Remove the nut and No. 1 chain tensioner assembly from the timing chain cover assembly.
      NOTE:

      Make sure that the plunger, check ball assembly and spring do not come out.

   3. Use tape to hold the plunger inside the No. 1 chain tensioner assembly.
      NOTE:

      • Make sure that the plunger, check ball assembly and spring do not come out.
      • If the No. 1 chain tensioner assembly comes apart, reinstall the parts as shown in the illustration.

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        *a	Plunger	*b	Check ball assembly
        *c	Spring	*d	No. 1 chain tensioner assembly body

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1

   Camshaft Timing Exhaust Gear Assembly

   *2

   Camshaft Timing Oil Control Valve Assembly (Exhaust Camshaft Timing Gear Bolt Assembly)

   1. Using a wrench, hold the hexagonal portion of the exhaust camshaft sub-assembly.
      NOTE:

      Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube with the wrench.

   2. Using a 5 mm hexagon socket wrench, remove the 3 bolts.
   3. Remove the camshaft timing exhaust gear assembly and camshaft timing oil control valve assembly (exhaust camshaft timing gear bolt assembly) from the exhaust camshaft sub-assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the 20 bolts and timing chain cover assembly from the camshaft housing sub-assembly, cylinder head sub-assembly, cylinder block sub-assembly, stiffening crankcase assembly and oil pump assembly.

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the timing chain cover assembly by prying between the cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly with a screwdriver with its tip wrapped with 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 assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using a screwdriver, remove the 2 crankshaft timing gear keys from the crankshaft.

      HINT: 

      Tape the screwdriver tip before use.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using an 8 mm socket wrench, remove the 2 bolts and fuel pump lifter guide from the No. 4 camshaft bearing cap.

1. Fig 1: Camshaft Housing Sub-Assembly Loosening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Uniformly loosen and remove the 17 bolts in the order shown in the illustration.
   2. Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver.
      NOTE:

      Be careful not to damage the contact surfaces of the cylinder head sub-assembly and camshaft housing sub-assembly.

      HINT: 

      Tape the screwdriver tip before use.

1. Fig 2: Camshaft Bearing Cap Loosening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	No. 1 Camshaft Bearing Cap	*2	No. 2 Camshaft Bearing Cap
   *3	No. 3 Camshaft Bearing Cap	*4	No. 4 Camshaft Bearing Cap

   1. Remove the 9 bolts in the order shown in the illustration.
   2. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 2 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap from the camshaft housing sub-assembly.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the 16 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the 16 valve stem caps from the cylinder head sub-assembly.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using an 8 mm socket wrench, remove the 2 bolts, No. 1 water by-pass pipe and water by-pass pipe gasket from the cylinder head sub-assembly.

1. Fig 3: Cylinder Head Sub-Assembly Loosening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Front of Engine

   -

   -

   1. Using a 12 mm socket wrench, uniformly loosen the 10 cylinder head set bolts in the order shown in the illustration. Remove the 10 cylinder head set bolts and 6 plate washers.
      NOTE:

      • Be careful not to drop the plate washers into the cylinder head sub-assembly.
      • Warpage or cracking of the cylinder head sub-assembly may result from removing the cylinder head set bolts in the incorrect order.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

   2. Remove the cylinder head sub-assembly from the cylinder block sub-assembly.

Refer to PROCEDURE - Step 79

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.
      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.

Refer to PROCEDURE - Step 3

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using a 12 mm hexagon socket wrench, remove the oil filter union from the stiffening crankcase assembly.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Nut

   -

   -

   1. Remove the 10 bolts and 2 nuts.
   2. Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut through the applied sealer and remove the oil pan sub-assembly.
      NOTE:

      • Be careful not to damage the contact surfaces of the stiffening crankcase assembly and oil pan sub-assembly.
      • Be careful not to damage the oil pan sub-assembly flange.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using an 8 mm socket wrench, remove the bolt, oil strainer sub-assembly and oil strainer gasket from the stiffening crankcase assembly.

Refer to PROCEDURE - Step 4

Refer to PROCEDURE - Step 6

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Remove the 10 bolts.
   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.
      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.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using a 10 mm hexagon socket wrench, remove the straight screw plug and gasket from the stiffening crankcase assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: It is not necessary to remove the ring pins unless they are being replaced.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: It is not necessary to remove the straight pins unless they are being replaced.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002