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Disassembly [09/2022 - ]: Procedure

WARNING: This page is about a different car, the 2025 Toyota GR Corolla, 2024 Toyota GR Corolla, and 2023 Toyota GR Corolla. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE SPARK PLUG 

    Refer to PROCEDURE - Step 3

  2. REMOVE OIL PRESSURE AND TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 2

  3. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side) 

    Refer to PROCEDURE - Step 5

  4. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side) 

    Refer to PROCEDURE - Step 6

  5. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side) 

    Refer to PROCEDURE - Step 2

  6. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side) 

    Refer to PROCEDURE - Step 3

  7. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9 [09/2022 - 11/2022] , or refer to PROCEDURE - Step 9 [11/2022 - ]

  8. REMOVE WATER INLET WITH WATER PUMP HOUSING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8 [09/2022 - 11/2022] , or refer to PROCEDURE - Step 8 [11/2022 - ]

  9. REMOVE OIL FILLER CAP ASSEMBLY 
    1. Remove the oil filler cap assembly from the cylinder head cover sub-assembly.
      GTY1019892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE OIL FILLER CAP GASKET 
    1. Remove the oil filler cap gasket from the oil filler cap assembly.
      GTY1019893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 2 [09/2022 - 11/2022] , or refer to PROCEDURE - Step 2 [11/2022 - ]

  12. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 

    Refer to PROCEDURE - Step 2 [09/2022 - 11/2022] , or refer to PROCEDURE - Step 2 [11/2022 - ]

  13. REMOVE VACUUM PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 10 [09/2022 - 09/2024] , or refer to PROCEDURE - Step 10 [09/2024 - ]

  14. REMOVE CRANKSHAFT PULLEY ASSEMBLY 
    1. Using SST, hold the crankshaft pulley assembly and loosen the crankshaft pulley set bolt. Further loosen the crankshaft pulley set bolt until 2 or 3 threads remain screwed into the crankshaft.
      GTY1020043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
      • SST: 09213-54015 
      • SST: 09330-00021 
    2. Using SST and the crankshaft pulley set bolt, remove the crankshaft pulley assembly and crankshaft pulley set bolt.
      GTY1019593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Pulley Set Bolt
      *a Hold
      *b Turn
      • 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.

  15. REMOVE OUTLET WATER SUB-ASSEMBLY 
    1. Remove the 2 nuts, outlet water sub-assembly and outlet water gasket from the cylinder head sub-assembly.
      GTY1019895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 17 bolts and cylinder head cover sub-assembly from the cylinder head sub-assembly.
      GTY1019897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 cylinder head cover gaskets from the cylinder head cover sub-assembly.
      GTY1019894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 camshaft bearing cap oil hole gaskets from the No. 1 camshaft bearing cap and fuel pump lifter housing.
      GTY1020479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE SPARK PLUG TUBE GASKET 
    1. Using a screwdriver, pry out the 3 spark plug tube gaskets from the cylinder head cover sub-assembly.
      GTY1020258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

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

      HINT: 

      Tape the screwdriver tip before use.

  18. REMOVE NO. 1 VACUUM PUMP BRACKET 
    1. Remove the 2 bolts and No. 1 vacuum pump bracket from the cylinder head sub-assembly.
      GTY1106909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 3 bolts and engine mounting bracket RH from the No. 2 timing chain cover assembly.
      GTY1019886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 2 TIMING CHAIN COVER ASSEMBLY 
    1. Remove the 8 bolts.
      GTY1107119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 2 timing chain cover assembly from the cylinder head sub-assembly by prying the No. 2 timing chain cover assembly with a screwdriver with its tip wrapped with protective tape.
      GTY1107118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TIMING CHAIN COVER OIL SEAL 

    Refer to PROCEDURE - Step 6 [09/2022 - 11/2022] , or refer to PROCEDURE - Step 12 [11/2022 - 09/2024] , or refer to PROCEDURE - Step 15 [09/2024 - ]

  22. REMOVE TIMING CHAIN COVER ASSEMBLY 

    Refer to PROCEDURE - Step 12 [09/2022 - 11/2022] , or refer to PROCEDURE - Step 18 [11/2022 - 09/2024] , or refer to PROCEDURE - Step 21 [09/2024 - ]

  23. SET VALVE TIMING 
    1. Temporarily install the crankshaft pulley bolt.
    2. Rotate the crankshaft clockwise and make sure that the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly is at the top.
      GTY1108849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
    3. Check that the crankshaft timing gear key as shown in the illustration.
      GTY1019552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Timing Gear Key
      *a Approximately 27°
    4. Remove the crankshaft pulley bolt.

      HINT: 

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

  24. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Turn the stopper plate of the No. 1 chain tensioner assembly clockwise to release the lock and push in the plunger.
      GTY1020528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Stopper Plate
      *2 Plunger
    2. Turn the stopper plate counterclockwise to set the lock.
    3. Insert a pin into the stopper plate hole.
      GTY1019910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 bolts and No. 1 chain tensioner assembly from the cylinder block sub-assembly.
      GTY1020485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the chain tensioner gasket from the No. 1 chain tensioner assembly.
      GTY1019913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE TIMING CHAIN GUIDE 
    1. Remove the 2 nut and timing chain guide from the damper plate spacer.
      GTY1019911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE DAMPER PLATE SPACER 
    1. Remove the damper plate spacers from the No. 2 camshaft bearing cap.
      GTY1019912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE CHAIN TENSIONER SLIPPER 
    1. Remove the bolt and chain tensioner slipper from the cylinder head sub-assembly.
      GTY1020012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE CHAIN SUB-ASSEMBLY 
    1. Remove the chain sub-assembly.
      GTY1020507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE NO. 1 CHAIN VIBRATION DAMPER 
    1. Remove the 2 bolts and No. 1 chain vibration damper.
      GTY1020010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET 
    1. Remove the crankshaft timing gear or sprocket from the crankshaft.
      GTY1020506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE CRANKSHAFT TIMING GEAR KEY 
    1. Using a screwdriver, remove the 2 crankshaft timing gear keys from the crankshaft.
      GTY1019614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      HINT: 

      Tape the screwdriver tip before use.

  32. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Using a wrench, hold the hexagonal portion of the exhaust camshaft sub-assembly.
      GTY1020504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the cylinder head sub-assembly or 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 from the exhaust camshaft sub-assembly.
      GTY1020159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 Camshaft Timing Valve Assembly
  33. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Using a wrench, hold the hexagonal portion of the intake camshaft sub-assembly.
      GTY1020007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

    2. Using a 5 mm hexagon socket wrench, remove the 3 bolts.
    3. Remove the camshaft timing gear assembly and camshaft timing valve assembly from the intake camshaft sub-assembly.
      GTY1020227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Timing Valve Assembly
  34. REMOVE FUEL PUMP LIFTER GUIDE 
    1. Remove the 2 bolts and fuel pump lifter guide from the fuel pump lifter housing.
      GTY1107130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FUEL PUMP LIFTER HOUSING 
    1. Remove the 3 bolts and fuel pump lifter housing from the cylinder head sub-assembly.
      GTY1107129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE CAMSHAFT POSITION SENSOR HOLDER 
    1. Remove the bolt and camshaft position sensor holder from the cylinder head sub-assembly.
      GTY1109177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE CAMSHAFT BEARING CAP 
    1. Remove the 18 bolts.
      GTY1105095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Camshaft Bearing Cap
      *2 No. 4 Camshaft Bearing Cap
      *3 No. 6 Camshaft Bearing Cap
    2. Remove the No. 2 camshaft bearing cap, 6 No. 4 camshaft bearing caps and No. 6 camshaft bearing cap from the No. 1 camshaft bearing cap, camshaft bearing cap and No. 5 camshaft bearing cap.

      HINT: 

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

  38. REMOVE EXHAUST CAMSHAFT SUB-ASSEMBLY 
    1. Remove the exhaust camshaft sub-assembly from the cylinder head sub-assembly.
      GTY1020404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE INTAKE CAMSHAFT SUB-ASSEMBLY 
    1. Remove the intake camshaft sub-assembly from the cylinder head sub-assembly.
      GTY1019539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE NO. 1 CAMSHAFT BEARING CAP 
    1. Remove the No. 1 camshaft bearing cap from the cylinder head sub-assembly.
      GTY1107127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE NO. 5 CAMSHAFT BEARING CAP 
    1. Remove the No. 5 camshaft bearing cap from the cylinder head sub-assembly.
      GTY1107126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Remove the 12 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.

      GTY1020029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE VALVE LASH ADJUSTER ASSEMBLY 
    1. Remove the 12 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.

      GTY1020509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE VALVE STEM CAP 
    1. Remove the 12 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.

      GTY1020023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE CYLINDER HEAD SUB-ASSEMBLY 
    1. Using a 12 mm socket wrench, uniformly loosen the 8 cylinder head set bolts in the order shown in the illustration. Remove the 8 cylinder head set bolts and 8 plate washers.
      Fig 1: Cylinder Head Bolts Loosening Sequence
      GTY1106534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 3 bolts and cylinder head sub-assembly from the cylinder block sub-assembly.
  46. REMOVE CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 8 [09/2022 - 11/2022] , or refer to PROCEDURE - Step 8 [11/2022 - 09/2024] , or refer to PROCEDURE - Step 8 [09/2024 - ]

  47. REMOVE OIL FILTER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  48. REMOVE OIL FILTER UNION 
    GTY1252419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a 12 mm hexagon socket wrench, remove the oil filter union from the oil filter bracket sub-assembly.
  49. REMOVE OIL COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 8

  50. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY 
    1. Remove the 3 bolts and oil filter bracket sub-assembly from the cylinder block sub-assembly.
      GTY1251242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 gaskets.
      GTY1020026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE OIL PAN DRAIN PLUG 
    1. Remove the oil pan drain plug and oil pan drain gasket from the No. 2 oil pan sub-assembly.
      GTY1020499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Remove the 10 bolts and 2 nuts.
      GTY1019432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
    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.
      GTY192227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to damage the contact surfaces of the No. 2 oil pan sub-assembly and oil pan sub-assembly.
      • Be careful not to damage the oil pan sub-assembly flange.
  53. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Remove the 13 bolts and oil pan sub-assembly from the crankshaft bearing cap.
      GTY1019736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the 2 bolts, oil strainer sub-assembly and oil strainer gasket from the crankshaft bearing cap.
      GTY1019747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE ENGINE BALANCER ASSEMBLY 
    1. Remove the 4 bolts and engine balancer assembly from the cylinder block sub-assembly.
      GTY1019748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. REMOVE BALANCESHAFT HOUSING SPACER 
    1. Remove the 4 balanceshaft housing spacers from the cylinder block sub-assembly.
      GTY1019741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE REAR ENGINE OIL SEAL 

    Refer to PROCEDURE - Step 4 [09/2022 - 11/2022] , or refer to PROCEDURE - Step 4 [11/2022 - 09/2024] , or refer to PROCEDURE - Step 6 [09/2024 - ]

  58. REMOVE STUD BOLT 
    NOTE:

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

  59. REMOVE RING PIN 
    NOTE:

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

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