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Engine Unit: Disassembly: Disassembly

HINT: 

When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side.

  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
  2. REMOVE OIL FILLER CAP HOUSING 
    1. Remove the 2 bolts, filler cap housing and gasket.
      Fig 1: Locating VVT Sensor Bolts (For Bank 1)
      GTY142087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE SPARK PLUG  . Refer to REMOVAL - Step 36
  4. REMOVE VVT SENSOR 
    1. for Bank 1:

      Remove the 2 bolts and 2 VVT sensors.

      Fig 2: Locating VVT Sensors Bolts
      GTY121435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Bank 2:

      Remove the 2 bolts and 2 VVT sensors.

      Fig 3: Locating VVT Sensors Bolts
      GTY148144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE CAMSHAFT POSITION SENSOR 
    1. Remove the bolt and camshaft position sensor.
      Fig 4: Locating Camshaft Position Sensor Bolt
      GTY131206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE CRANKSHAFT POSITION SENSOR 
    1. Remove the bolt and crankshaft position sensor.
      Fig 5: Locating Crankshaft Position Sensor Bolt
      GTY148145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
    1. for Bank 1:

      Remove the bolt and oil control valve.

      Fig 6: Locating Oil Control Valve Bolt
      GTY148146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the O-ring from the valve.

    2. for Bank 2:

      Remove the bolt and oil control valve.

      Fig 7: Locating Oil Control Valve Bolt
      GTY130258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the O-ring from the valve.

  8. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. Remove the 2 water drain cock plugs from the water drain cocks.
      Fig 8: Locating Wire Harness Clamp Bracket Bolt
      GTY127605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 water drain cocks from the cylinder block.
  9. REMOVE CAMSHAFT TIMING CONTROL MOTOR LH  . Refer to REMOVAL - Step 26
  10. REMOVE CAMSHAFT TIMING CONTROL MOTOR RH  . Refer to REMOVAL - Step 27
  11. REMOVE WIRE HARNESS CLAMP BRACKET 
    Fig 9: Locating Front Water By-Pass Joint Nuts
    GTY135145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the bolt and wire harness clamp bracket.
  12. REMOVE OIL FILTER ELEMENT  . Refer to REPLACEMENT - Step 3
  13. REMOVE OIL FILTER BRACKET  . Refer to REMOVAL - Step 29
  14. REMOVE WATER PUMP PULLEY  . Refer to REMOVAL - Step 17
  15. REMOVE FRONT WATER BY-PASS JOINT 
    1. Remove the 4 nuts, water by-pass joint and 2 gaskets.
      Fig 10: Removing Spark Plug Tube Gasket
      GTY148147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE SPARK PLUG TUBE GASKET 
    1. Using a screwdriver, pry out the 8 plug tube gaskets.
      Fig 11: Locating Loosening Sequence Of Cylinder Head Cover Bolts
      GTY128819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Tape the screwdriver tip before use.

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Remove the fuel pump spacer.
      Fig 12: Locating Gaskets And O-Rings
      GTY123198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the fuel pump spacer gasket.
    3. Remove the 15 bolts in the order shown in the illustration. Then remove the 2 seal washers, cylinder head cover and gasket.

      HINT: 

      Make sure the removed parts are returned to the same places they were removed from.

    4. Remove the 4 gaskets and 2 O-rings from the camshaft bearing caps (No. 2, No. 3 and No. 7).
      Fig 13: Locating Camshaft Bearing Cap Gaskets And O-Rings
      GTY148274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH 
    1. Remove the fuel pump spacer.
      Fig 14: Locating Gaskets And O-Rings
      GTY147953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the fuel pump spacer gasket.
    3. Remove the 15 bolts in the order shown in the illustration. Then remove the 2 seal washers, cylinder head cover and gasket.

      HINT: 

      Make sure the removed parts are returned to the same places they were removed from.

    4. Remove the 4 gaskets and 2 O-rings from the camshaft bearing caps (No. 1, No. 3 and No. 6).
      Fig 15: Locating Camshaft Bearing Cap Gaskets And O-Rings
      GTY148275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE OIL CONTROL VALVE FILTER 
    1. for LH:
      1. Remove the 2 bolts, cylinder head cover spacer, gasket and valve filter.
        Fig 16: Locating Cylinder Head Cover Spacer Bolts (For LH)
        GTY129670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for RH:
      1. Remove the 2 bolts, cylinder head cover spacer, gasket and valve filter.
        Fig 17: Locating Cylinder Head Cover Spacer Bolts (For RH)
        GTY147424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY  . Refer to REMOVAL - Step 24
  21. REMOVE CRANKSHAFT PULLEY  . Refer to REMOVAL - Step 30
  22. REMOVE WATER PUMP  . Refer to REMOVAL - Step 18
  23. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY  . Refer to REMOVAL - Step 35
  24. REMOVE WATER INLET PIPE  . Refer to REMOVAL - Step 36
  25. REMOVE FRONT CRANKSHAFT OIL SEAL 
    Fig 18: Identifying Timing Marks On Crankshaft Timing Gear And Camshaft Timing Gears
    GTY148160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Place the timing chain cover on wooden blocks.
    2. Using a screwdriver and wooden block, pry out the oil seal.
      NOTE:

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

      HINT: 

      Tape the screwdriver tip before use.

  26. SET NO. 1 CYLINDER TO TDC / COMPRESSION 
    1. Temporarily install the crankshaft pulley bolt.
    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

      HINT: 

      If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

    3. Remove the crankshaft pulley bolt.
      Fig 19: Identifying Timing Marks On Crankshaft Timing Gear And Camshaft Timing Gears
      GTY148152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH 
    1. Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.
      Fig 20: Moving Stopper Plate Counterclockwise
      GTY148458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.
      Fig 21: Locating Chain Tensioner Bolts
      GTY148459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts, chain tensioner and gasket.
      Fig 22: Locating Chain Tensioner Bolts
      GTY105142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH 
  29. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH 

    Remove the 2 bolts and chain vibration damper.

    Fig 23: Locating Chain Vibration Damper Bolts
    GTY103304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH 
    1. While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.
      Fig 24: Removing Camshaft Bolt
      GTY128946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt with a 12 mm hexagon wrench.
      Fig 25: Removing Camshaft Bolt
      GTY129334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to damage the cylinder head with the wrench.
      • Do not disassemble the camshaft timing gear.
    3. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.
      Fig 26: Locating Chain Tensioner Bolts
      GTY141623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the cylinder head with the wrench.

    4. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket LH.
    5. Remove the No. 1 and No. 2 chains from the gears.
  31. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY 
    1. Remove the 2 bolts and chain tensioner.
      Fig 27: Moving Stopper Plate Clockwise
      GTY147449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH 
    1. Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.
      Fig 28: Moving Stopper Plate Counterclockwise
      GTY148460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.
      Fig 29: Locating Chain Tensioner Bolts
      GTY135066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and chain tensioner.
      Fig 30: Locating Chain Tensioner Bolts
      GTY102782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH 
  34. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH 
    1. Remove the 2 bolts and vibration damper.
      Fig 31: Locating Vibration Damper Bolts
      GTY104155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH 
    1. While raising up the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.
      Fig 32: Removing Camshaft Bolt
      GTY147447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt with a 12 mm hexagon wrench.
      Fig 33: Holding Hexagonal Portion Of Camshaft
      GTY100047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to damage the cylinder head with the wrench.
      • Do not disassemble the camshaft timing gear.
    3. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.
      Fig 34: Locating Chain Tensioner Bolts
      GTY125175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the cylinder head with the wrench.

    4. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket RH.
    5. Remove the No. 1 and No. 2 chains from the gears.
  36. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY 
    1. Remove the 2 bolts and chain tensioner.
      Fig 35: Locating Chain Tensioner Bolts
      GTY103397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE CRANKSHAFT TIMING GEAR KEY 
    1. Using a screwdriver, remove the 2 timing gear keys from the crankshaft.
      Fig 36: Identifying Water Jacket Spacers
      GTY137916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE CAMSHAFT BEARING CAP LH  See step  10
  39. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH  See step  11
  40. REMOVE CAMSHAFT BEARING CAP RH  See step  14
  41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH  See step  15
  42. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Remove the 32 valve rocker arms from the cylinder head.

      HINT: 

      Arrange the removed parts in the correct order.

  43. REMOVE VALVE LASH ADJUSTER ASSEMBLY 
    1. Remove the 32 valve lash adjusters from the cylinder head.

      HINT: 

      Arrange the removed parts in the correct order.

  44. REMOVE VALVE STEM CAP 
    1. Remove the 32 valve stem caps from the cylinder head.

      HINT: 

      Arrange the removed parts in the correct order.

  45. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH  See step  7
  46. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH  See step  7
  47. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    1. Remove the 2 water jacket spacers from the cylinder head.
      Fig 37: Identifying Cylinder Block Water Jacket Spacers From Cylinder Head
      GTY105207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be sure to remove the water jacket spacers. If not, they may fall and become damaged when the cylinder block is inverted.

  48. REMOVE NO. 1 HEAT EXCHANGER COVER 
    1. Remove the 12 bolts and 2 nuts.
      Fig 38: Removing Heat Exchanger Cover
      GTY143808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the heat exchanger by prying between the heat exchanger and cylinder block with a screwdriver.
      Fig 39: Identifying Heat Exchanger By Prying Between Heat Exchanger & Cylinder Block
      GTY105199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Tape the screwdriver tip before use.

  49. REMOVE VENTILATION PIPE GASKET 
    1. Using a screwdriver, pry out the ventilation pipe gasket.
      Fig 40: Removing Ventilation Pipe Gasket
      GTY103493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Tape the screwdriver tip before use.

  50. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Remove the 13 bolts and 2 nuts.
      Fig 41: Locating No 2 Oil Pan Bolts And Nuts
      GTY121668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the blade of oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.
      Fig 42: Inserting Blade Of Oil Pan Seal Cutter Between Oil Pans
      GTY145991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the contact surfaces of the oil pans.

  51. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY 
    1. Remove the 14 bolts and 2 nuts.
      Fig 43: Locating No 1 Oil Pan Bolts And Nuts
      GTY139813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Be sure to clean the bolts and stud bolts, and check the threads for cracks or other damage.

    2. Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.
      Fig 44: Removing No 2 Oil Pan
      GTY141669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the contact surfaces of the cylinder block and oil pan.

      HINT: 

      Tape the screwdriver tip before use.

  52. REMOVE NO. 1 OIL PAN BAFFLE PLATE 
    1. Remove the 4 bolts and baffle plate.
      Fig 45: Locating No. 1 Oil Pan Baffle Plate Bolts - AWD
      GTY135353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE NO. 2 OIL PAN BAFFLE PLATE 
    1. Remove the 4 bolts and baffle plate.
      Fig 46: Locating No. 2 Oil Pan Baffle Plate Bolts - AWD
      GTY120821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE ENGINE OIL LEVEL SENSOR  . Refer to REMOVAL - Step 8
  55. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the 2 bolts, oil strainer and O-ring.
      Fig 47: Locating Oil Strainer Bolts
      GTY135783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. REMOVE ENGINE REAR OIL SEAL RETAINER 
    1. Remove the 6 bolts.
      Fig 48: Locating Engine Rear Oil Seal Retainer Bolts
      GTY105136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, pry out the oil seal retainer.
      Fig 49: Prying Out Oil Seal Retainer
      GTY102032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Tape the screwdriver tip before use.

  57. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY 
    1. Remove the bolt and oil drain pipe.
      Fig 50: Locating Oil Drain Pipe Bolt
      GTY130607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring.
  58. REMOVE REAR CRANKSHAFT OIL SEAL 
    Fig 51: Removing Rear Crankshaft Oil Seal
    GTY140495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Place the oil seal retainer on wooden blocks.
    2. Using a screwdriver and hammer, tap out the oil seal.
  59. REMOVE STRAIGHT PIN 
    NOTE:

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

  60. REMOVE STUD BOLT 
    NOTE:

    If the stud bolts are deformed or their threads are damaged, replace them.

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