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Home >> Toyota >> 2023 >> Prius LE >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical System - Service Information (3 Of 4) >> ENGINE UNIT (for PHEV Model) >> Disassembly [03/2023 - ] >> Procedure

Disassembly [03/2023 - ]: Procedure

  1. REMOVE SPARK PLUG 
    Refer to PROCEDURE - Step 3
  2. REMOVE KNOCK CONTROL SENSOR 
    Refer to PROCEDURE - Step 2
  3. REMOVE OIL PRESSURE AND TEMPERATURE SENSOR 
    Refer to PROCEDURE - Step 2
  4. REMOVE OIL PRESSURE CONTROL VALVE ASSEMBLY 
    Refer to PROCEDURE - Step 3
  5. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY 
    Refer to PROCEDURE - Step 2
  6. REMOVE CAM TIMING OIL CONTROL SOLENOID O-RING 
    Refer to PROCEDURE - Step 3
  7. REMOVE CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY 
    Refer to PROCEDURE - Step 2
  8. REMOVE CAM TIMING CONTROL MOTOR O-RING 

    Refer to PROCEDURE - Step 3

  9. REMOVE OIL FILLER CAP ASSEMBLY 
    1. GTY1029239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE OIL FILLER CAP GASKET 
    1. GTY997263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE CRANKSHAFT POSITION SENSOR 
    Refer to PROCEDURE - Step 2
  12. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 

    Refer to PROCEDURE - Step 2

  13. REMOVE CRANKSHAFT PULLEY ASSEMBLY 
    1. GTY1149729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Pulley Bolt - -
      *a Hold - -
      Turn - -
      1. Using SST, hold the crankshaft pulley assembly and loosen the crankshaft pulley bolt.
        • SST: 09213-54015 
        • SST: 09330-00021 
      2. Further loosen the crankshaft pulley bolt until 2 or 3 threads remain screwed into the crankshaft.
      3. Apply lubricant to the threads and end of SST.
        • SST: 09950-50013 
          1. 09951-05010
          2. 09952-05010
          3. 09953-05020
          4. 09954-05070
          5. 09957-04010
      4. Using SST and the crankshaft pulley bolt, remove the crankshaft pulley assembly and crankshaft pulley bolt.
  14. REMOVE WATER HOSE SUB-ASSEMBLY 
    1. GTY1146278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. GTY1146280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE WATER OUTLET SUB-ASSEMBLY 
    1. GTY1155729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the 2 bolts and water outlet sub-assembly from the cylinder head sub-assembly.
  16. REMOVE WATER OUTLET GASKET 
    1. GTY1152179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE WATER BY-PASS OUTLET 
    1. GTY1154512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the 3 bolts and water by-pass outlet from the cylinder head sub-assembly.
  18. REMOVE WATER OUTLET PIPE GASKET 
    1. GTY1152173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side) 
    Refer to PROCEDURE - Step 1
  20. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side) 
    Refer to PROCEDURE - Step 2
  21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. GTY1143487Courtesy 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 11 gaskets from the cylinder head cover sub-assembly.
      4. Remove the gasket from the No. 1 camshaft bearing cap.
  22. REMOVE SPARK PLUG TUBE GASKET 
    1. GTY1140816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver with its tip wrapped with protective tape, 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.

  23. REMOVE ENGINE MOUNTING BRACKET RH 
    1. GTY1140316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE STRAIGHT SCREW PLUG 
    1. GTY1154599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 10 mm hexagon socket wrench, remove the straight screw plug from the No. 2 timing chain cover assembly.
  25. REMOVE NO. 2 TIMING CHAIN COVER ASSEMBLY 
    1. GTY1158798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the 20 bolts.
      2. 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.

  26. REMOVE TIMING CHAIN COVER OIL SEAL 
    1. GTY1143681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver with its tip wrapped with protective tape 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.

  27. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 
    1. GTY1143686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the crankshaft pulley bolt.
    2. GTY1147236Courtesy 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. Rotate the crankshaft clockwise and align the crankshaft timing gear key as shown in the illustration.
      2. If the timing marks are not aligned, rotate the crankshaft clockwise and realign the timing marks.
    3. GTY1151907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. While holding the hexagonal portion of the exhaust camshaft sub-assembly, remove the crankshaft pulley bolt.
        NOTE:

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

  28. REMOVE OIL PUMP DRIVE CHAIN SUB-ASSEMBLY 
    1. GTY1155559Courtesy 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. Using SST, hold the crankshaft pulley assembly and 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.
  29. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 
    1. GTY1158644Courtesy 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 exhaust 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-hexagon socket wrench, remove the bolt and camshaft timing gear assembly from the intake camshaft sub-assembly.
  30. REMOVE CHAIN SUB-ASSEMBLY 
    1. GTY1029117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. GTY1141382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the bolt.
      2. Remove the nut and No. 1 chain tensioner assembly.
        NOTE:

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

    2. GTY1150096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tape *b Plunger
      *c Check Ball Assembly *d Spring
      *e No. 1 Chain Tensioner Assembly Body *f Oil Hole
      1. 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.
  32. REMOVE CHAIN TENSIONER SLIPPER 
    1. GTY1029235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE NO. 1 CHAIN VIBRATION DAMPER 
    1. GTY1029120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. GTY1075713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Exhaust Gear Assembly *2 Camshaft Timing Valve Assembly
      *a Hold - -
      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 valve assembly.
  35. REMOVE TIMING CHAIN COVER ASSEMBLY 
    1. GTY1142933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the 20 bolts.
      2. Remove the timing chain cover assembly by prying between the cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly, oil pump 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, oil pump assembly, stiffening crankcase assembly and timing chain cover assembly.

  36. REMOVE OIL NOZZLE VALVE SUB-ASSEMBLY 
    1. GTY1138586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE CRANKSHAFT TIMING GEAR KEY 
    NOTE:

    Be careful not to damage the crankshaft.
    1. GTY1145663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver with its tip wrapped with protective tape, remove the 2 crankshaft timing gear keys.
  38. REMOVE FUEL PUMP LIFTER GUIDE 
    1. GTY1145675Courtesy 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.
  39. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY 
    1. GTY1140659Courtesy 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 with its tip wrapped with protective tape.
        NOTE:

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

  40. REMOVE CAMSHAFT BEARING CAP 
    1. GTY1270881Courtesy 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. Uniformly loosen and 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.
  41. REMOVE INTAKE CAMSHAFT SUB-ASSEMBLY 
    1. GTY1029237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE EXHAUST CAMSHAFT SUB-ASSEMBLY 
    1. GTY1029125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. GTY997271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE VALVE LASH ADJUSTER ASSEMBLY 
    1. GTY998017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE VALVE STEM CAP 
    1. GTY998018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE NO. 3 STRAIGHT SCREW WITH HEAD PLUG 
    1. GTY1146821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 10 mm hexagon socket wrench, remove the No. 3 straight screw with head plug from the cylinder head sub-assembly.
  47. REMOVE CYLINDER HEAD SUB-ASSEMBLY 
    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.
    1. GTY1159402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plate Washer - -
      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.
      2. Remove the cylinder head sub-assembly from the cylinder block sub-assembly.
  48. REMOVE CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 84

  49. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    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.
    1. GTY1029158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE OIL FILTER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  51. REMOVE OIL FILTER UNION 
    1. GTY1146950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 12 mm straight hexagon wrench, remove the oil filter union from the stiffening crankcase assembly.
  52. REMOVE OIL PAN DRAIN PLUG 
    1. GTY1143635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE OIL PAN SUB-ASSEMBLY 
    1. GTY1149705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut - -
      1. Remove the 12 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.
      3. Clean and inspect the bolts, nuts and stud bolts.
  54. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. GTY1155010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the bolt, oil strainer sub-assembly and oil strainer gasket.
  55. REMOVE ENGINE OIL LEVEL SENSOR 
    Refer to PROCEDURE - Step 4
  56. REMOVE ENGINE BALANCER ASSEMBLY 
    NOTE:

    Do not disassemble the engine balancer assembly.
    1. GTY1154180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE OIL PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 6

  58. REMOVE STIFFENING CRANKCASE ASSEMBLY 
    1. GTY1159183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the 7 bolts.
      2. Using a screwdriver with its tip wrapped with protective tape, 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.

  59. REMOVE STRAIGHT SCREW PLUG 
    1. GTY1146506Courtesy 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.
  60. REMOVE REAR ENGINE OIL SEAL 
    1. GTY1029245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. GTY1147954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, remove the bolt and wire harness clamp bracket.
  62. REMOVE STUD BOLT 
    NOTE:

    If a stud bolt is deformed or its threads are damaged, replace it.
    1. GTY1147545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an E6 "TORX" socket wrench, remove the stud bolt from the stiffening crankcase assembly.
      2. Using an E6 "TORX" socket wrench, remove the stud bolt from the timing chain cover assembly.
      3. w/ Stud Bolt:
        1. Using an E8 "TORX" socket wrench, remove the stud bolt from the cylinder head sub-assembly.
  63. REMOVE RING PIN 
    NOTE:

    It is not necessary to remove the ring pins unless they are being replaced.
    1. GTY1156318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Camshaft Housing Sub-assembly Upper Side *B Stiffening Crankcase Assembly Side
  64. REMOVE STRAIGHT PIN 
    NOTE:

    It is not necessary to remove the straight pins unless they are being replaced.
    1. GTY1029582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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