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Home >> Lexus >> 2016 >> GS 200t Base >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical - Service Information >> Engine Unit >> Disassembly [10/2015 - ] >> Procedure

Disassembly [10/2015 - ]: Procedure

  1. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 3

  2. REMOVE FUEL DELIVERY PIPE (for Port Injection) 

    Refer to PROCEDURE - Step 3

  3. REMOVE PORT FUEL INJECTOR ASSEMBLY (for Port Injection) 

    Refer to PROCEDURE - Step 4

  4. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (for Direct Injection) 

    Refer to PROCEDURE - Step 4

  5. REMOVE DIRECT FUEL INJECTOR ASSEMBLY (for Direct Injection) 

    Refer to PROCEDURE - Step 5

  6. REMOVE FUEL INJECTOR SEAL (for Direct Injection) 

    Refer to PROCEDURE - Step 6

  7. REMOVE FUEL PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 4

  8. REMOVE VACUUM PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 5

  9. REMOVE NO. 9 ENGINE WIRE 
    1. Disconnect the connector from the oil pressure switching valve assembly.
      GTY642219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the 3 clamps and remove the No. 9 engine wire from the water by-pass pipe assembly and water inlet.
  10. REMOVE WATER BY-PASS PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 5

  11. REMOVE NO. 4 WATER BY-PASS PIPE 
    1. Slide the clamp and disconnect the No. 4 water by-pass hose from the oil cooler assembly.
      GTY642220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 nuts, bolt and No. 4 water by-pass pipe from the cylinder block sub-assembly and water inlet housing.
    3. Remove the gasket from the water inlet housing.
  12. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 4

  13. REMOVE WATER INLET HOUSING 

    Refer to PROCEDURE - Step 7

  14. REMOVE THERMOSTAT (for Cylinder Block) 

    Refer to PROCEDURE - Step 8

  15. REMOVE SPARK PLUG 

    Refer to PROCEDURE - Step 4

  16. REMOVE KNOCK SENSOR 

    Refer to PROCEDURE - Step 2

  17. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  18. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 2

  19. REMOVE CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 2

  20. REMOVE PCV VALVE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  21. REMOVE NO. 1 PCV CASE 
    1. Remove the 6 bolts and 2 nuts.
      GTY679049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 1 PCV case by prying between the No. 1 PCV case and cylinder block sub-assembly with a screwdriver.
      GTY642222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to damage the contact surfaces of the cylinder block sub-assembly.
      • Do not reuse the No. 1 PCV case.

      HINT: 

      Tape the screwdriver tip before use.

  22. REMOVE CRANKSHAFT PULLEY ASSEMBLY 
    1. Using SST, hold the crankshaft pulley assembly and loosen the crankshaft pulley set bolt until 2 or 3 threads are screwed into the crankshaft.
      • SST: 09213-54015 
      • SST: 09330-00021 
      GTY621341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn

      HINT: 

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)

    2. Using SST and the crankshaft pulley set bolt, remove the crankshaft pulley assembly from the crankshaft.
      • SST: 09950-50013 
        1. 09951-05010
        2. 09952-05010
        3. 09953-05020
        4. 09954-05011
        5. 09957-04010
      GTY650313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Pulley Set Bolt
      *a Hold
      Turn

      HINT: 

      Apply lubricant to the threads and end of SST.

  23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 12

  24. REMOVE SPARK PLUG TUBE GASKET 
    NOTE:

    Be sure not to disconnect the PCV hose or the No. 4 PCV hose from the cylinder head cover sub-assembly.

    1. Remove the spark plug tube gasket from the cylinder head cover sub-assembly with a screwdriver.
      GTY639869Courtesy 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.

  25. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY 

    Refer to PROCEDURE - Step 2

  26. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 3

  27. REMOVE WATER OUTLET SUB-ASSEMBLY 
    1. Slide the clamp and disconnect the No. 6 water by-pass hose from the water outlet sub-assembly.
      GTY679101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts, nut and water outlet sub-assembly from the timing chain cover assembly.
    3. Remove the O-ring from the timing chain cover assembly.
  28. REMOVE TIMING CHAIN COVER ASSEMBLY 

    Refer to PROCEDURE - Step 19

  29. REMOVE TIMING CHAIN COVER OIL SEAL 

    Refer to PROCEDURE - Step 20

  30. REMOVE TIMING CHAIN COVER PLATE 
    1. Remove the 4 bolts, timing chain cover plate and gasket from the timing chain cover assembly.
      GTY642458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Temporarily install the crankshaft pulley set bolt.
    2. Rotate the crankshaft clockwise so that the timing marks (groove) on the camshaft timing gear assembly and camshaft timing exhaust gear assembly and the crankshaft pulley set key of the crankshaft timing sprocket are as shown in the illustration.
      GTY813482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Pulley Set Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark (Groove) - -

      HINT: 

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

    3. Remove the crankshaft pulley set bolt.
  32. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Allow the plunger to extend slightly, and then rotate the stopper plate counterclockwise to release the lock. Once the lock is released, push the plunger into the No. 1 chain tensioner assembly.
      GTY625031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Stopper Plate
      *b Plunger
    2. Move the stopper plate clockwise to set the lock, and then insert a pin into the stopper plate hole.
      GTY631643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
    3. Remove the nut, bolt, No. 1 chain tensioner assembly and gasket from the cylinder block sub-assembly.
      GTY642466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE TIMING CHAIN GUIDE 
    1. Remove the bolt and timing chain guide from the No. 1 camshaft bearing cap.
      GTY518504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE CHAIN TENSIONER SLIPPER 
    1. Remove the bolt and chain tensioner slipper from the cylinder head sub-assembly.
      GTY679102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE CHAIN SUB-ASSEMBLY 
  36. REMOVE NO. 1 CHAIN VIBRATION DAMPER 
    1. Remove the 2 bolts and No. 1 chain vibration damper from the cylinder head sub-assembly and cylinder block sub-assembly.
      GTY642463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE CRANKSHAFT TIMING SPROCKET 
    1. Remove the crankshaft timing sprocket from the crankshaft.
      GTY642467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Hold the hexagonal portion of the camshaft with a wrench and remove the camshaft timing gear bolt and camshaft timing gear assembly from the camshaft.
      GTY632582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:
      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.
      • Do not disassemble the camshaft timing gear assembly.
  39. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Hold the hexagonal portion of the No. 2 camshaft with a wrench and remove the bolt and camshaft timing exhaust gear assembly from the No. 2 camshaft.
      GTY628085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:
      • Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.
      • Do not disassemble the camshaft timing exhaust gear assembly.
  40. REMOVE OIL PIPE SUB-ASSEMBLY 
    1. Remove the bolt and oil pipe sub-assembly from the No. 4 camshaft bearing cap.
      GTY501916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY 
    1. Uniformly loosen and remove the 22 bearing cap bolts in the sequence shown in the illustration.
      Fig 1: Camshaft Housing Sub-Assembly Bolts Loosening Sequence
      GTY510749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver.
      GTY642434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

      HINT: 

      Tape the screwdriver tip before use.

  42. REMOVE NO. 3 WATER BY-PASS PIPE 
    1. Remove the 3 bolts, No. 3 water by-pass pipe and gasket from the cylinder head sub-assembly.
      GTY642436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE CAMSHAFT BEARING CAP 
    1. Remove the 11 bearing cap bolts in the sequence shown in the illustration.
      Fig 2: Camshaft Bearing Cap Bolts Loosening Sequence
      GTY510286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 1, No. 2, No. 3 and No. 4 camshaft bearing caps from the camshaft housing sub-assembly.

      HINT: 

      Arrange the removed parts in the correct order.

  44. REMOVE OIL CONTROL VALVE FILTER 
    1. Remove the oil control valve filter from the No. 1 camshaft bearing cap.
      GTY501913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE CAMSHAFT 
    1. Remove the camshaft from the camshaft housing sub-assembly.
  46. REMOVE NO. 2 CAMSHAFT 
    1. Remove the No. 2 camshaft from the camshaft housing sub-assembly.
  47. REMOVE NO. 1 CAMSHAFT BEARING 
    1. Remove the No. 1 camshaft bearing from the No. 1 camshaft bearing cap.
      GTY501921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE NO. 2 CAMSHAFT BEARING 
    1. Remove the No. 2 camshaft bearing from the camshaft housing sub-assembly.
      GTY501923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Remove the 16 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

      HINT: 

      Arrange the removed parts in the correct order.

  50. REMOVE VALVE LASH ADJUSTER ASSEMBLY 
    1. Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

      HINT: 

      Arrange the removed parts in the correct order.

  51. REMOVE VALVE STEM CAP 
    1. Remove the 16 valve stem caps from the cylinder head sub-assembly.

      HINT: 

      Arrange the removed parts in the correct order.

  52. REMOVE CYLINDER HEAD SUB-ASSEMBLY 

    See step  24

  53. REMOVE CYLINDER HEAD GASKET 

    See step  25

  54. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    1. Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.
      GTY653814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.

  55. REMOVE OIL FILTER CAP ASSEMBLY 

    Refer to PROCEDURE - Step 2

  56. REMOVE OIL FILTER BRACKET CLIP 
    1. Remove the oil filter bracket clip from the stiffening crankcase assembly.
      GTY642433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE OIL COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 5

  58. REMOVE OIL PAN DRAIN PLUG 
    1. Remove the oil pan drain plug and gasket from the oil pan sub-assembly.
  59. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Remove the 11 bolts and 2 nuts.
      GTY679098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut off the applied sealer and remove the oil pan sub-assembly.
      GTY145991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 stiffening crankcase assembly flange.
  60. REMOVE ENGINE OIL LEVEL SENSOR 

    Refer to PROCEDURE - Step 3

  61. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the 3 bolts, oil strainer sub-assembly and gasket from the stiffening crankcase assembly and engine balancer assembly.
      GTY642444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE NO. 1 OIL PAN BAFFLE PLATE 
    1. Remove the 4 bolts and No. 1 oil pan baffle plate from the engine balancer assembly.
      GTY679097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. REMOVE ENGINE BALANCER ASSEMBLY 
    1. Remove the 5 bolts and engine balancer assembly from the stiffening crankcase assembly.
      GTY642440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not disassemble the engine balancer assembly.

  64. REMOVE ENGINE OIL TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 3

  65. REMOVE STIFFENING CRANKCASE ASSEMBLY 
    1. Remove the 8 bolts.
      GTY642430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly at the places shown in the illustration.
      GTY642428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the contact surfaces of the cylinder block sub-assembly and stiffening crankcase assembly.

      HINT: 

      Tape the screwdriver tip before use.

  66. REMOVE REAR ENGINE OIL SEAL 
    1. Remove the rear engine oil seal from the cylinder block sub-assembly.
  67. REMOVE STUD BOLT 
    NOTE:

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

  68. REMOVE RING PIN 
    NOTE:

    It is not necessary to remove the ring pin unless it is being replaced.

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