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Disassembly [09/2014 - ]: Procedure

  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
    1. Remove the oil filler cap sub-assembly from the oil filler cap housing.
    2. Remove the oil filler cap gasket from the oil filler cap sub-assembly.
  2. REMOVE OIL FILLER CAP HOUSING 
    1. Remove the 2 bolts, oil filler cap housing and oil filler cap housing gasket.
      GTY502609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE SPARK PLUG 

    Refer to PROCEDURE - Step 8

  4. REMOVE OIL PAN DRAIN PLUG 
    1. Remove the oil pan drain plug and gasket from the No. 2 oil pan sub-assembly.
  5. REMOVE VVT SENSOR (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 4

  6. REMOVE VVT SENSOR (for Exhaust Side of Bank 2) 

    Refer to PROCEDURE - Step 5

  7. REMOVE VVT SENSOR (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 7

  8. REMOVE VVT SENSOR (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 9

  9. REMOVE CAMSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 3

  10. REMOVE CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 3

  11. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY LH 

    Refer to PROCEDURE - Step 2

  12. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH 

    Refer to PROCEDURE - Step 5

  13. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. Remove the cylinder block water drain cock plug from each cylinder block water drain cock sub-assembly.
      GTY505666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 2
      *B for Bank 1
    2. Remove each cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.
  14. REMOVE CAMSHAFT TIMING CONTROL MOTOR WITH EDU ASSEMBLY LH 

    Refer to PROCEDURE - Step 3

  15. REMOVE CAMSHAFT TIMING CONTROL MOTOR WITH EDU ASSEMBLY RH 

    Refer to PROCEDURE - Step 9

  16. REMOVE FRONT WATER BY-PASS JOINT 
    1. Remove the 4 nuts, front water by-pass joint and 2 gaskets.
      GTY502570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE OIL FILTER CAP ASSEMBLY 
    1. Using SST, loosen the oil filter cap assembly 4 turns, align the cap ribs vertically, and drain the remaining engine oil from the oil filter cap assembly.
      GTY509286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cap Rib
      • SST: 09228-06501 

      HINT: 

      Set a container below the oil filter cap assembly before loosening the oil filter cap assembly.

    2. Remove the oil filter cap assembly.
    3. Remove the oil filter element and O-ring from the oil filter cap assembly.
      NOTE:

      Do not use any tools to remove the O-ring in order to prevent the oil filter cap assembly from being damaged. Be sure to remove it by hand.

      GTY514982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Filter Element
      *2 Oil Filter Cap Assembly
      *3 O-ring
  18. REMOVE OIL THERMOSTAT HOUSING ASSEMBLY 

    Refer to PROCEDURE - Step 3

  19. REMOVE OIL FILTER BRACKET 
    1. Remove the 2 bolts and oil filter bracket stay.
      GTY518617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts, 2 nuts and oil filter bracket.
      GTY502571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 gaskets from the timing chain cover assembly.
  20. REMOVE CRANKSHAFT PULLEY 

    Refer to PROCEDURE - Step 9

  21. REMOVE NO. 1 V-BANK COVER BRACKET (for Bank 1) 
    1. Remove the No. 1 V-bank cover bracket from the cylinder head cover sub-assembly LH.
      GTY502572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE NO. 1 V-BANK COVER BRACKET (for Bank 2) 
    1. Remove the No. 1 V-bank cover bracket from the cylinder head cover sub-assembly.
      GTY499788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Remove the fuel pump spacer gasket.
      GTY499791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly LH and cylinder head cover gasket LH.

      HINT: 

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

    3. Remove the 2 oil hole gaskets and 2 O-rings from the camshaft bearing caps.
      GTY502575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the fuel pump spacer gasket.
      GTY499787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.

      HINT: 

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

    3. Remove the 2 oil hole gaskets and 2 O-rings from the camshaft bearing caps.
      GTY502568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE SPARK PLUG TUBE GASKET 
    1. Using a screwdriver, pry out the 8 spark plug tube gaskets from each cylinder head sub-assembly and cylinder head LH.
      GTY148801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Tape the screwdriver tip before use.

  26. REMOVE OIL CONTROL VALVE FILTER LH 
    1. Remove the 2 bolts, cylinder head cover spacer LH and gasket.
      GTY509918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Control Valve Filter LH
      *2 Gasket
      *3 Cylinder Head Cover Spacer LH
    2. Remove the oil control valve filter LH from the cylinder head cover spacer LH.
  27. REMOVE OIL CONTROL VALVE FILTER RH 
    1. Remove the 2 bolts, cylinder head cover spacer RH and gasket.
      GTY506083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Control Valve Filter RH
      *2 Gasket
      *3 Cylinder Head Cover Spacer RH
    2. Remove the oil control valve filter RH from the cylinder head cover spacer RH.
  28. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the bolt, 6 mm hexagon bolt and V-ribbed belt tensioner assembly.
      GTY498058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 6 mm Hexagon Bolt
  29. REMOVE ENGINE WATER PUMP ASSEMBLY 
    1. Remove the 5 bolts, engine water pump assembly and water pump gasket from the timing chain cover assembly.
      GTY502467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE TIMING CHAIN COVER ASSEMBLY 

    Refer to PROCEDURE - Step 49

  31. REMOVE OIL PUMP RELIEF VALVE PLUG 
    1. Remove the oil pump relief valve plug and gasket from the timing chain cover assembly.
      GTY947608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL 

    Refer to PROCEDURE - Step 50

  33. REMOVE INLET WATER PIPE 
    1. Remove the inlet water pipe.
      GTY496701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the inlet water pipe.
  34. REMOVE NO. 1 OIL PIPE 

    Refer to PROCEDURE - Step 2

  35. REMOVE NO. 2 OIL PIPE 

    Refer to PROCEDURE - Step 3

  36. REMOVE NO. 3 OIL PIPE 

    Refer to PROCEDURE - Step 4

  37. REMOVE SCAVENGING PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 5

  38. SET NO. 1 CYLINDER TO TDC / COMPRESSION 
    1. Temporarily tighten the crankshaft pulley set bolt.
    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear assembly 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.

      GTY1084005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark *b Timing Mark Position
      *c Knock Pin Position *d Approximately 2°
      *e Approximately 45° *f Approximately 16°
      *g Upward *h Approximately 20°
      *i Approximately 33° *j Key
  39. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1) 
    1. Turn the stopper plate clockwise to release the lock, and fully push the plunger into the No. 1 chain tensioner assembly.
      GTY512883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Stopper Plate
      *b Plunger
      *c Pin
    2. Turn the stopper plate counterclockwise to set the lock, and insert a pin into the stopper plate hole.
    3. Remove the 2 bolts and No. 1 chain tensioner assembly.
      GTY496687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the chain tensioner gasket.
  40. REMOVE CHAIN TENSIONER SLIPPER (for Bank 1) 
    1. Remove the chain tensioner slipper.
      GTY518001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 1) 
    1. Remove the 2 bolts and No. 1 chain vibration damper.
      GTY518598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE CHAIN SUB-ASSEMBLY (for Bank 1) 
    1. While pushing down the No. 3 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to secure it in place.
      GTY518711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
      *b Plunger
      *c Push
    2. Using a wrench, hold the hexagonal portion of the camshaft and loosen the bolt with a 12 mm hexagon socket wrench.
      NOTE:
      • Be careful not to damage the cylinder head with the wrench.
      • Do not disassemble the camshaft timing gear assembly.
      GTY507823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
    3. Using a wrench, hold the hexagonal portion of the camshaft and loosen the bolt with a wrench.
      GTY512567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
      NOTE:

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

    4. Remove the 2 bolts. Then with the chain sub-assembly and No. 2 chain sub-assembly still attached to the gears, remove the camshaft timing gear assembly, camshaft timing exhaust gear and crankshaft timing sprocket LH.
    5. Remove the chain sub-assembly and No. 2 chain sub-assembly from the gears.
  43. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY 
    1. Remove the 2 bolts and No. 3 chain tensioner assembly.
      GTY127623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2) 
    1. Turn the stopper plate clockwise to release the lock, and fully push the plunger into the tensioner.
      GTY516343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plunger
      *b Stopper Plate
      *c Pin
    2. Turn the stopper plate counterclockwise to set the lock, and insert a pin of 1.0 mm (0.0394 in.) diameter into the stopper plate hole.
    3. Remove the 2 bolts and No. 1 chain tensioner assembly.
      GTY498147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE CHAIN TENSIONER SLIPPER (for Bank 2) 
    1. Remove the chain tensioner slipper.
      GTY499801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 2) 
    1. Remove the 2 bolts and No. 1 chain vibration damper.
      GTY499770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE CHAIN SUB-ASSEMBLY (for Bank 2) 
    1. While pushing up the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to secure it in place.
      GTY521646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Push
      *b Plunger
      *c Pin
    2. Using a wrench, hold the hexagonal portion of the camshaft and loosen the bolt with a 12 mm hexagon socket wrench.
      NOTE:
      • Be careful not to damage the cylinder head with the wrench.
      • Do not disassemble the camshaft timing gear assembly.
      GTY511317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
    3. Using a wrench, hold the hexagonal portion of the camshaft and loosen the bolt with a wrench.
      GTY504579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
      NOTE:

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

    4. Remove the 2 bolts. Then with the chain sub-assembly and No. 2 chain sub-assembly still attached to the gears, remove the camshaft timing gear assembly, camshaft timing exhaust gear and crankshaft timing gear.
    5. Remove the chain sub-assembly and No. 2 chain sub-assembly from the gears.
  48. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY 
    1. Remove the 2 bolts and No. 2 chain tensioner assembly.
      GTY127622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE CRANKSHAFT TIMING GEAR KEY 
    1. Using a screwdriver, remove the 2 crankshaft timing gear keys from the crankshaft.
      GTY122372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE OIL REFLECTOR PLATE LH 
    1. Remove the 2 bolts and oil reflector plate LH from the cylinder head LH.
      GTY502108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE CAMSHAFT BEARING CAP (for Bank 1) 

    Refer to PROCEDURE - Step 14

  52. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 15

  53. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 16

  54. REMOVE OIL REFLECTOR PLATE RH 
    1. Remove the 2 bolts and oil reflector plate RH from the cylinder head sub-assembly.
      GTY502466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE CAMSHAFT BEARING CAP (for Bank 2) 

    Refer to PROCEDURE - Step 18

  56. REMOVE CAMSHAFT 

    Refer to PROCEDURE - Step 19

  57. REMOVE NO. 2 CAMSHAFT 

    Refer to PROCEDURE - Step 20

  58. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Remove the 32 No. 1 valve rocker arm sub-assemblies from the cylinder head LH and cylinder head sub-assembly.

      HINT: 

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

      GTY512341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Valve Adjusting Shim
      *2 Cylinder Head Valve Rocker Arm Pivot
  59. REMOVE CYLINDER HEAD VALVE ROCKER ARM PIVOT LH 
    1. Remove the 16 cylinder head valve rocker arm pivots from the cylinder head LH.
  60. REMOVE CYLINDER HEAD VALVE ROCKER ARM PIVOT RH 
    1. Remove the 16 cylinder head valve rocker arm pivots from the cylinder head sub-assembly.
  61. REMOVE CYLINDER HEAD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 14

  62. REMOVE CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 15

  63. REMOVE CYLINDER HEAD LH 

    Refer to PROCEDURE - Step 12

  64. REMOVE NO. 2 CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 13

  65. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    1. Remove the 2 cylinder block water jacket spacers from the cylinder block sub-assembly.
      NOTE:

      Be sure to remove the cylinder block water jacket spacers. Otherwise, they may fall out and be damaged when the cylinder block is inverted.

      GTY148823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. REMOVE HEAT EXCHANGER ASSEMBLY 
    1. Remove the bolt.
      GTY502453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 11 bolts and 2 nuts.
      GTY502454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the heat exchanger assembly by prying between the heat exchanger assembly and cylinder block sub-assembly with a screwdriver.

      HINT: 

      Tape the screwdriver tip before use.

      GTY127604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. REMOVE VENTILATION PIPE GASKET 
    1. Using a screwdriver, pry out the ventilation pipe gasket.

      HINT: 

      Tape the screwdriver tip before use.

      GTY148826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Remove the 15 bolts and 2 nuts.
      GTY509329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
    2. Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and No. 2 oil pan sub-assembly. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.
      GTY467508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Pan Seal Cutter
      NOTE:

      Be careful not to damage the contact surfaces of the oil pan sub-assembly and No. 2 oil pan sub-assembly.

  69. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Remove the 14 bolts and 2 nuts.
      GTY515094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut

      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 sub-assembly and cylinder block with a screwdriver.
      GTY508023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 1 Side
      *B for Bank 2 Side
      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.

  70. REMOVE NO. 1 OIL PAN BAFFLE PLATE 
    1. Remove the 8 bolts and No. 1 oil pan baffle plate.
      GTY499825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the 2 bolts, oil strainer sub-assembly and O-ring.
      GTY517320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. REMOVE ENGINE REAR OIL SEAL RETAINER 
    1. Remove the 6 bolts.
      GTY496704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, pry out the engine rear oil seal retainer.
      GTY516044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

      Be careful not to damage the engine rear oil seal retainer and cylinder block sub-assembly.

      HINT: 

      Tape the screwdriver tip before use.

  73. REMOVE ENGINE REAR OIL SEAL 
    1. Place the engine rear oil seal retainer on wooden blocks.
      GTY516342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
    2. Using a screwdriver and hammer, tap out the engine rear oil seal.
  74. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY 
    1. Remove the bolt and oil drain pipe sub-assembly.
      GTY505935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the oil drain pipe sub-assembly.
  75. REMOVE STUD BOLT 
    NOTE:

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

  76. REMOVE RING PIN 
    NOTE:

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

  77. REMOVE STRAIGHT PIN 
    NOTE:

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

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