Engine Unit: Disassembly

1. Remove the oil filler cap sub-assembly.
   Fig 1: Removing Oil Filler Cap Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the ventilation valve sub-assembly.
   Fig 2: Removing Ventilation Valve Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and camshaft position sensor.
   Fig 3: Removing Bolt & Camshaft Position Sensor

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and crankshaft position sensor.
   Fig 4: Removing Bolt & Crankshaft Position Sensor

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and camshaft timing oil control valve.
   Fig 5: Removing Bolt & Camshaft Timing Oil Control Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 19 bolts, 2 nuts, head cover and 2 gaskets.
   Fig 6: Removing Bolts, Nuts, Head Cover & Gaskets

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover.
2. Check that the timing marks of the camshaft timing gear and sprocket are aligned with the timing marks of the bearing cap No.1, as shown in Fig 7.
   Fig 7: Aligning Timing Marks Of Camshaft Timing Gear & Sprocket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, loosen the crankshaft pulley bolt.

   SST 09213-54015 (91651-60855), 09330-00021 

   Fig 8: Loosening Crankshaft Pulley Bolt Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, remove the crankshaft pulley bolt and crankshaft pulley.

   SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05021) 

   Fig 9: Removing Crankshaft Pulley Bolt & Crankshaft Pulley Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the drain plug and gasket.
2. Remove the 18 bolts and 2 nuts.
   Fig 10: Removing Bolts & Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the oil pan sub-assembly No.2.

   SST 09032-00100 

   NOTE: Be careful not to damage the contact surfaces of the oil pans.
   Fig 11: Inserting Blade Of SST Between Oil Pans

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts, 2 nuts, oil strainer and gasket.
   Fig 12: Removing Bolts, Nuts, Oil Strainer & Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 16 bolts and 2 nuts.
   Fig 13: Removing Bolts & Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.
   NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

   HINT:

   Tape the screwdriver tip before use.

   Fig 14: Removing Oil Pan By Prying Between Oil Pan & Cylinder Block With Screwdriver

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the O-ring.
   Fig 15: Removing O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 19 bolts and 2 nuts as shown in Fig 16.
   Fig 16: Removing Timing Chain Cover Bolts & Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.

   HINT:

   Tape the screwdriver tip before use.

   NOTE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and timing chain cover.
   Fig 17: Removing Timing Chain Cover By Prying Between Timing Chain Cover With Screwdriver

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 O-rings.
   Fig 18: Removing O-Rings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a 10 mm socket hexagon wrench, remove the timing chain cover plug.
   Fig 19: Removing Timing Chain Cover Plug Using Socket Hexagon Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 8 bolts, water pump and gasket.
   Fig 20: Removing Bolts, Water Pump & Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts, timing chain guide and O-ring.
   Fig 21: Removing Bolts, Timing Chain Guide & O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate's hole.
   Fig 22: Identifying Chain Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the bolt, nut, chain tensioner assembly No.1 and gasket.
   Fig 23: Removing Bolt, Nut, Chain Tensioner Assembly No.1 & Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and tensioner slipper.
   Fig 24: Removing Bolt & Tensioner Slipper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt, nut, and vibration damper.
Fig 25: Removing Vibration Damper, Bolt & Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the chain.

1. Remove the crankshaft timing gear from the crankshaft.
   Fig 26: Removing Crankshaft Timing Gear From Crankshaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Uniformly loosen and remove the 21 bearing cap bolts and 20 washers on the camshafts in the sequence shown in Fig 27.
   Fig 27: Identifying Removing Sequence Of Bearing Cap Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the oil delivery pipe and O-ring from the bearing caps.
   Fig 28: Removing Oil Delivery Pipe & O-Ring From Bearing Caps

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 9 bearing caps.
   Fig 29: Removing Bearing Caps

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the camshaft sub-assembly.
   Fig 30: Removing Camshaft Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the No.2 camshaft sub-assembly.
   Fig 31: Removing No. 2 Camshaft Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 16 valve rocker arm sub-assembly.
   Fig 32: Removing Valve Rocker Arm Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Fix the camshaft with a vise and then remove the sprocket bolt and camshaft timing sprocket.
   NOTE: Be careful not to damage the camshaft.
   Fig 33: Removing Sprocket Bolt & Camshaft Timing Sprocket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check the lock of the camshaft timing gear.
   1. Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked.
      NOTE: Be careful not to damage the camshaft.
2. Release the lock pin.
   1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in Fig 34.

      HINT:

      2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece.

   2. Break through the tape of the advance side path and the retard side path on the opposite side to the hole of the advance side path, as shown in the illustration.
      Fig 34: Identifying Advance Side Path & Retard Side Path On Opposite Side

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Apply approximately 200 kPa (2.0 kgf*cm² , 28 psi) of air pressure to the two broken paths.
      CAUTION: Some oil splashing will occur. Cover the paths with a shop rag.
      Fig 35: Applying Air Pressure To Camshaft Timing Gear Both Path

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path.

      OK: Gear rotates in the advance direction. 

      HINT:

      This operation releases the lock pin for the most retarded position.

   5. When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path, in that order.
      NOTE: Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.
      Fig 36: Identifying Camshaft Timing Gear Turning Position

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check for smooth rotation.
   1. Rotate the camshaft timing gear within its movable range several times, but do not turn it to the most retarded position. Check that the gear rotates smoothly.

      OK: Gear rotates in the advance direction. 

      CAUTION: Do not use an air pressure to perform the smooth operation check.
4. Check the lock in the most retarded position.
   1. Confirm that the camshaft timing gear is locked at the most retarded position.

1. Remove the fringe bolt and camshaft timing gear.
   NOTE:

   • Be sure not to remove the other 3 bolts.
   • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.
     Fig 37: Removing Fringe Bolt & Camshaft Timing Gear

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Uniformly loosen the 10 bolts in the sequence shown in Fig 38. Remove the 10 cylinder head bolts and plate washers.
   NOTE:

   • Be careful not to drop washers into the cylinder head.
   • Head warpage or cracking could result from removing bolts in an incorrect order.
2. Remove the cylinder head.
   Fig 38: Identifying Removing Sequence Of Cylinder Head Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the cylinder head and gasket.

1. Move the stopper plate downward to release the lock, and push the plunger deep into the tensioner.
2. Move the stopper plate upward to set the lock, and insert a hexagon wrench into the stopper plate's hole.
   Fig 39: Pushing Plunger Deep Into Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the bolt and chain vibration damper No.2.
   Fig 40: Removing Bolt & Chain Vibration Damper No. 2

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts and chain vibration damper No.3.
   Fig 41: Removing Bolts & Chain Vibration Damper No. 3

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the hexagon wrench from the tensioner assembly No.2.
2. Remove the nut and chain tensioner assembly No.2.
   Fig 42: Removing Nut & Chain Tensioner Assembly No. 2

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt, balancer shaft drive gear shaft and balancer shaft drive gear.
2. Remove the crankshaft timing sprocket No.2 and chain.
   Fig 43: Removing Crankshaft Timing Sprocket No. 2 & Chain

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts and vibration damper No.4.
   Fig 44: Removing Bolts & Vibration Damper No. 4

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 pulley set keys from the crankshaft.
   Fig 45: Removing Pulley Set Keys From Crankshaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the oil filter.

   SST 09228-07501 

   Fig 46: Removing Oil Filter Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 27 mm socket wrench, remove the oil filter union.
   Fig 47: Removing Oil Filter Union Using Socket Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts and nut from the oil filter bracket.
2. Remove the 2 screw plugs and 2 gaskets from the oil filter bracket.
   Fig 48: Removing Bolts & Nut From Oil Filter Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the oil filter bracket gasket and O-ring.
   Fig 49: Removing Oil Filter Bracket Gasket & O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a hexagon wrench, remove the oil filter bracket union.
   Fig 50: Removing Oil Filter Bracket Union Using Hexagon Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the taper screw plug from the cylinder block.
   Fig 51: Removing Taper Screw Plug From Cylinder Block

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 6 bolts.
2. Using a screwdriver with its tip taped, pry out the oil seal retainer.

   HINT:

   Tape the screwdriver tip before use.

   Fig 52: Prying Out Oil Seal Retainer Using Screwdriver

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the valve stem caps from the cylinder head.

   HINT:

   Arrange the removed parts in the correct order.

   Fig 53: Removing Valve Stem Caps From Cylinder Head

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the valve lash adjusters from the cylinder head.

   HINT:

   Arrange the removed parts in the correct order.

   Fig 54: Removing Valve Lash Adjusters From Cylinder Head

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.

   SST 09202-70020 (09202-00010) 

   Fig 55: Compressing Compression Spring & Removing Valve Retainer Locks Using SST & Wooden Blocks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the retainer, compression spring, and valve.

   HINT:

   Arrange the removed parts in the correct order.

   Fig 56: Removing Retainer, Compression Spring & Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.

   SST 09202-70020 (09202-00010) 

   Fig 57: Compressing Compression Spring & Removing Valve Retainer Locks Using SST & Wooden Blocks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the retainer, compression spring, and valve.

   HINT:

   Arrange the removed parts in the correct order.

   Fig 58: Removing Retainer, Compression Spring & Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using needle-nose pliers, remove the oil seals.
Fig 59: Removing Oil Seals Using Needle-Nose Pliers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the valve spring seats from the cylinder head.

1. Using an 8 mm hexagon wrench, remove the screw plug.
2. Remove the oil control valve filter and gasket.
   Fig 60: Removing Screw Plug Using Hexagon Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a 10 mm hexagon wrench, remove the 3 screw plugs and 3 gaskets.
   NOTE: If water leaks from the w/ head straight screw plug No.1 or the plug corrodes, replace it.
   Fig 61: Removing Screw Plugs & Gaskets Using Hexagon Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a 19 mm hexagon wrench, remove the screw plug and gasket.
   NOTE: If water leaks from the w/ head straight screw plug No.2 or the plug corrodes, replace it.
Fig 62: Removing Screw Plug & Gasket Using Hexagon Wrench
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

   HINT:

   • Keep the bearing, connecting rod and cap together.
   • Arrange the piston and connecting rod assemblies in the correct order.
     Fig 63: Removing Carbon From Top Of Cylinder Using Ridge Reamer

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Arrange the removed parts in the correct order.

1. Uniformly loosen the 10 bearing cap bolts, in several steps, in the sequence shown in Fig 64.

   HINT:

   • Keep the lower bearings and crankshaft bearing caps together.
   • Arrange the thrust washers in the correct order.
   Fig 64: Identifying Removal Sequence Of Bearing Cap Bolts
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Lift out the crankshaft.
3. Remove the upper bearings and upper thrust washers from the cylinder block.

   HINT:

   Arrange the main bearing caps, bearings and thrust washers in the correct order.

Fig 65: Removing Upper Bearings & Upper Thrust Washers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Arrange the removed parts in the correct order.

1. Using a piston ring expander, remove the 2 compression rings.
2. Using a piston ring expander, remove the oil ring rail.
3. Remove the oil ring expander by hand.

   HINT:

   Arrange the piston rings in the correct order.

   Fig 66: Removing Oil Ring Rail Using Piston Ring Expander

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the water drain cock sub-assembly from the cylinder block.
2. Remove the water drain cock plug from the water drain cock sub-assembly.
   Fig 67: Removing Water Drain Cock Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check the fitting condition between the piston and piston pin.
   1. Try to move the piston back and forth on the piston pin.

      If any movement is felt, replace the piston and pin as a set.

      Fig 68: Checking Fitting Condition Between Piston & Piston Pin

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the connecting rod from the piston.
   1. Using a screwdriver, pry off the snap rings from the piston.
      Fig 69: Prying Off Snap Rings From Piston Using Screwdriver

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).
      Fig 70: Gradually Heating Piston

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using a brass bar and plastic-faced hammer, lightly tap out the piston pin and remove the connecting rod.

      HINT:

      • The piston and pin are a matched set.
      • Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
      Fig 71: Tapping Out Piston Pin & Removing Connecting Rod Using Brass Bar & Hammer

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a 5 mm hexagon wrench, remove the oil nozzles.
   Fig 72: Removing Oil Nozzles Using Hexagon Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt.
   Fig 73: Removing Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the balancer shaft from the cylinder block.
   NOTE: When removing the balancer shaft, make sure to support the balancer shaft with both hands and avoid scratching the balancer shaft bearing on the cylinder block side.
   Fig 74: Removing Balancer Shaft From Cylinder Block

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Mount the head portion of the balancer shaft in a vise.
   NOTE: Be careful not to damage the balancer shaft.
2. Remove the bolt.
3. Remove the balancer shaft driven gear No.1 (*1), sliding key (*2), balancer shaft thrust washer No.1 (*3) and balancer shaft thrust spacer (*4).
   Fig 75: Removing Balancer Shaft Driven Gear No.1 & Sliding Key

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts.
   Fig 76: Removing Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the balancer shaft from the cylinder block.
   NOTE: When removing the balancer shaft, make sure to support the balancer shaft with both hands and avoid scratching the balancer shaft bearing on the cylinder block side.
   Fig 77: Removing Balancer Shaft From Cylinder Block

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Mount the head portion of the balancer shaft in a vise.
   NOTE: Be careful not to damage the balancer shaft.
2. Remove the bolt.
3. Remove the balancer shaft driven gear No.2 (*1) and balancer shaft thrust washer No.2 (*2).
   Fig 78: Removing Balancer Shaft Driven Gear No. 2 & Balancer Shaft Thrust Washer No. 2

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002