Engine Unit: Disassembly: Disassembly

WARNING: This page is about a different car, the 2010 Lexus GS 460. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE OIL FILLER CAP SUB-ASSEMBLY
REMOVE OIL FILLER CAP HOUSING
1. Remove the 2 bolts, oil filler cap housing and gasket.
  
  Fig 1: Identifying Cap Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPARK PLUG . Refer to REMOVAL - Step 16
REMOVE VVT SENSOR
1. for Bank 1:
  Remove the 2 bolts and 2 VVT sensors.
  
  Fig 2: Identifying VVT Sensors And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. for Bank 2:
  Remove the 2 bolts and 2 VVT sensors.
  
  Fig 3: Identifying VVT Sensors And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT POSITION SENSOR
1. Remove the bolt and camshaft position sensor.
  
  Fig 4: Identifying Camshaft Position Sensor Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT POSITION SENSOR
1. Remove the bolt and crankshaft position sensor.
  
  Fig 5: Identifying Crankshaft Position Sensor Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. for Bank 1:
  Remove the bolt and camshaft timing oil control valve assembly.
  
  Fig 6: Identifying Camshaft Timing Oil Control Valve Assembly Bolt - For Bank 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. for Bank 2:
  Remove the bolt and camshaft timing oil control valve assembly.
  
  Fig 7: Identifying Camshaft Timing Oil Control Valve Assembly Bolt - For Bank 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Remove the 2 cylinder block water drain cock plugs from the cylinder block water drain cocks.
  
  Fig 8: Identifying Cylinder Block Water Drain Cocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 cylinder block water drain cocks from the cylinder block.
REMOVE CAMSHAFT TIMING CONTROL MOTOR (for Bank 1) . Refer to REMOVAL - Step 10
REMOVE CAMSHAFT TIMING CONTROL MOTOR (for Bank 2) . Refer to REMOVAL - Step 9
REMOVE OIL FILTER ELEMENT . Refer to REPLACEMENT - Step 3
REMOVE OIL FILTER BRACKET
1. Remove the 3 bolts, filter bracket and 2 gaskets.
  
  Fig 9: Identifying Oil Filter Bracket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT WATER BY-PASS JOINT
1. Remove the 4 nuts, front water by-pass joint and 2 gaskets.
  
  Fig 10: Identifying Front Water By-Pass Joint Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPARK PLUG TUBE GASKET
1. Using a screwdriver, pry out the 8 spark plug tube gaskets.
  
  Fig 11: View Of Prying Out Spark Plug Tube Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
1. Remove the fuel pump spacer gasket.
  
  Fig 12: Identifying Fuel Pump Spacer Gasket And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 15 bolts, 2 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.
  HINT:
  
  Make sure that the removed parts are returned to the original places they were removed from.
3. Remove the 4 gaskets and 2 O-rings from the camshaft bearing caps (No. 2, No. 3, No. 7).
  
  Fig 13: Identifying Gaskets And Camshaft Bearing Caps (No. 2, No. 3, No. 7) O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
1. Remove the fuel pump spacer gasket.
  
  Fig 14: Identifying Fuel Pump Spacer Gasket And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 15 bolts, 2 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.
  HINT:
  
  Make sure that the removed parts are returned to the original places they were removed from.
3. Remove the 4 gaskets and 2 O-rings from the camshaft bearing caps (No. 1, No. 3, No. 6).
  
  Fig 15: Identifying Gaskets And Camshaft Bearing Caps (No. 1, No. 3, No. 6) O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL CONTROL VALVE FILTER
1. for Bank 1:
  1. Remove the 2 bolts, cylinder head cover spacer, gasket and valve filter.
    
    Fig 16: Identifying Cylinder Head Cover Spacer Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. for Bank 2:
  1. Remove the 2 bolts, cylinder head cover spacer, gasket and valve filter.
    
    Fig 17: Identifying Cylinder Head Cover Spacer Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
1. Remove the standard bolt, 6 mm hexagon wrench bolt and belt tensioner.
  
  Fig 18: Identifying Standard Bolt And Belt Tensioner 6 mm Hexagon Wrench Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT PULLEY See step 6
REMOVE WATER PUMP . Refer to REMOVAL - Step 16
REMOVE TIMING CHAIN COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 53
REMOVE INLET WATER PIPE . Refer to REMOVAL - Step 54
SET NO. 1 CYLINDER TO TDC/COMPRESSION
1. Temporarily tighten the pulley set 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.
  
  Fig 19: Identifying Timing Marks On Crankshaft Timing Gear And Camshaft Timing Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1)
1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
  
  Fig 20: Identifying Plunger And Stopper Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate hole.
3. Remove the 2 bolts and chain tensioner.
  
  Fig 21: Identifying Chain Tensioner Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CHAIN TENSIONER SLIPPER (for Bank 1)
REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 1)
1. Remove the 2 bolts and chain vibration damper.
  
  Fig 22: Identifying Chain Vibration Damper Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CHAIN SUB-ASSEMBLY (for Bank 1)
1. While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it in place.
  
  Fig 23: View Of Inserting Pin Into Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt with a 12mm hexagon wrench.
  
  Fig 24: View Of Holding Hexagonal Portion Of Camshaft With Wrench
  Courtesy 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 25: View Of Holding Hexagonal Portion Of Camshaft To Loosen Bolts
  Courtesy 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 assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket.
5. Remove the No. 1 and No. 2 chains from the gears.
REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
1. Remove the 2 bolts and chain tensioner.
  
  Fig 26: Identifying Chain Tensioner Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2)
1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
  
  Fig 27: Identifying Plunger And Stopper Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate hole.
3. Remove the 2 bolts and chain tensioner.
  
  Fig 28: Identifying Chain Tensioner Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CHAIN TENSIONER SLIPPER (for Bank 2)
REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 2)
1. Remove the 2 bolts and vibration damper.
  
  Fig 29: Identifying Vibration Damper Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CHAIN SUB-ASSEMBLY (for Bank 2)
1. While raising up the No. 2 chain tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it in place.
  
  Fig 30: View Of Inserting Pin Into Hole
  Courtesy 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 31: View Of Holding Hexagonal Portion Of Camshaft
  Courtesy 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 32: View Of Holding Hexagonal Portion Of Camshaft
  Courtesy 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 assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket.
5. Remove the No. 1 and No. 2 chains from the gears.
REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
1. Remove the 2 bolts and chain tensioner.
  
  Fig 33: Identifying Chain Tensioner Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT TIMING GEAR KEY
1. Using a screwdriver, remove the 2 timing gear keys from the crankshaft.
  
  Fig 34: Identifying Timing Gear Keys
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT BEARING CAP (for Bank 2) See step 15
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 2) See step 16
REMOVE CAMSHAFT BEARING CAP (for Bank 1) See step 10
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY (for Bank 1) See step 11
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.
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.
REMOVE VALVE STEM CAP
1. Remove the 32 valve stem caps from the cylinder head.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE CYLINDER HEAD SUB-ASSEMBLY (for Bank 1) See step 8
REMOVE CYLINDER HEAD SUB-ASSEMBLY (for Bank 2) See step 8
REMOVE CYLINDER BLOCK WATER JACKET SPACER
1. Remove the 2 cylinder block water jacket spacers from the cylinder head.
  
  Fig 35: Identifying Cylinder Block Water Jacket Spacers From Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Be sure to remove the cylinder block water jacket spacers. Otherwise, they may fall and become damaged when the cylinder block is inverted.
REMOVE OIL RETURN PIPE GASKET
1. Using a screwdriver, pry out the oil return pipe gasket.
  
  Fig 36: View Of Prying Out Oil Return Pipe Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE NO. 1 HEAT EXCHANGER COVER
1. Remove the 11 bolts and 2 nuts.
  
  Fig 37: Identifying Heat Exchanger Cover Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the heat exchanger by prying between the heat exchanger and cylinder block with a screwdriver.
  
  Fig 38: Identifying Heat Exchanger By Prying Between Heat Exchanger & Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE VENTILATION PIPE GASKET
1. Using a screwdriver, pry out the ventilation pipe gasket.
  
  Fig 39: View Of Removing Ventilation Pipe Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
1. Remove the 15 bolts and 2 nuts.
  
  Fig 40: Identifying Oil Pan Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Insert the blade of an oil pan cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.
  
  Fig 41: View Of Inserting Blade Of Oil Pan Seal Cutter Between Oil Pans
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Be careful not to damage the contact surfaces of the oil pans.
REMOVE OIL PAN SUB-ASSEMBLY
1. Remove the 14 bolts and 2 nuts.
  
  Fig 42: Identifying Oil Pan Bolts And Nuts
  Courtesy 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 sub-assembly by prying between the oil pan and cylinder block with a screwdriver.
  
  Fig 43: Identifying Contact Surfaces Of Cylinder Block & Oil Pan
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Be careful not to damage the contact surfaces of the cylinder block and oil pan sub-assembly.
  
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE NO. 1 OIL PAN BAFFLE PLATE
1. Remove the 8 bolts and No. 1 oil pan baffle plate.
  
  Fig 44: Identifying Baffle Plate & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL STRAINER SUB-ASSEMBLY
1. Remove the 2 bolts, oil strainer sub-assembly and O-ring.
  
  Fig 45: Identifying Oil Strainer Sub-Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE REAR OIL SEAL RETAINER
1. Remove the 6 bolts.
  
  Fig 46: Identifying Engine Rear Oil Seal Retainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, pry out the engine rear oil seal retainer.
  
  Fig 47: View Of Prying Out Oil Seal Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE OIL DRAIN PIPE SUB-ASSEMBLY
1. Remove the bolt and oil drain pipe sub-assembly.
  
  Fig 48: Identifying Oil Drain Pipe Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the O-ring.
REMOVE NO. 1 VENTILATION CONNECTOR
1. Remove the No. 1 ventilation connector.
  
  Fig 49: Identifying Ventilation Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  When removing the No. 1 ventilation connector, the ventilation tube may separate from the No. 1 ventilation connector. If this occurs, be sure to remove it from the cylinder block.
  
  If the ventilation tube comes off, check for deformation and damage. If normal, attach the ventilation tube to the No. 1 ventilation connector. If deformed or damaged, replace the No. 1 ventilation connector assembly.