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Engine Unit: Disassembly: Disassembly

  1. REMOVE ENGINE COVER JOINT 
    1. Remove the 3 joints.
      Fig 1: Location of Engine Cover Joint
      GTY312223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE SPARK PLUG  . Refer to REMOVAL - Step 2
  3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)  . Refer to REMOVAL - Step 2
  4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)  . Refer to REMOVAL - Step 1
  5. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)  . Refer to REMOVAL - Step 2
  6. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)  . Refer to REMOVAL - Step 1
  7. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
    1. Remove the oil filler cap from the cylinder head.
    2. Remove the gasket from the oil filler cap.
  8. REMOVE CRANKSHAFT POSITION SENSOR  . Refer to REMOVAL - Step 2
  9. REMOVE PCV VALVE  . Refer to REMOVAL - Step 2
  10. REMOVE PCV CASE 
    1. Remove the 8 bolts and 2 nuts.
      Fig 2: Location of Ventilation Case Sub-Assembly Bolts And Nuts
      GTY238525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the PCV case by prying between the PCV case and cylinder block with a screwdriver.
      Fig 3: Location of Ventilation Case
      GTY232432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the contact surfaces of the cylinder block and PCV case.

      HINT: 

      Tape the screwdriver tip before use.

  11. REMOVE SEPARATOR CASE 
    1. Remove the 2 bolts, separator case and gasket.
      Fig 4: Identifying Separator Case With Bolts
      GTY314345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 1 WATER BY-PASS PIPE 
    1. Remove the bolt, 2 nuts, water by-pass pipe and gasket.
      Fig 5: Location of Water By-Pass Pipe And Gasket Bolt And Nuts
      GTY311838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE WATER INLET  . Refer to REMOVAL - Step 6
  14. REMOVE THERMOSTAT  . Refer to REMOVAL - Step 7
  15. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY  . Refer to REMOVAL - Step 8
  16. REMOVE WATER PUMP ASSEMBLY  . Refer to REMOVAL - Step 9
  17. REMOVE WATER INLET HOUSING 
    1. Remove the 4 bolts, nut, water inlet housing and gasket.
      Fig 6: Location of Inlet Water Housing And Gasket Bolts And Nut
      GTY314677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE CRANKSHAFT PULLEY 
    1. Using SST, hold the crankshaft pulley and loosen the pulley bolt until 2 or 3 threads are screwed into the crankshaft.
      Fig 7: Holding Crankshaft Pulley
      GTY234895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09213-54015 
      • SST: 91551-80650 
      • SST: 09330-00021 
    2. Using SST and the pulley bolt, remove the crankshaft pulley.
      Fig 8: Removing Crankshaft Pulley Using SST
      GTY311286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-50013 
        1. 09954-05011
        2. 09951-05010
        3. 09952-05010
        4. 09953-05020
      TEXT IN ILLUSTRATION

      *1 Pulley Bolt

      HINT: 

      Apply lubricant to the threads and end of SST.

  19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY  . Refer to REMOVAL - Step 4
  20. REMOVE SPARK PLUG TUBE GASKET  . Refer to REMOVAL - Step 5
  21. REMOVE ENGINE MOUNTING BRACKET RH  . Refer to REMOVAL - Step 8
  22. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY  . Refer to REMOVAL - Step 10
  23. REMOVE TIMING CHAIN COVER TIGHT PLUG 
    1. Using a 14 mm hexagon wrench, remove the plug and gasket.
      Fig 9: Identifying Plug And Gasket
      GTY312189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE TIMING CHAIN COVER PLATE 
    1. Remove the 4 bolts, timing chain cover plate and gasket.
      Fig 10: Location of Timing Chain Cover Plate Bolts
      GTY312183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE TIMING CHAIN COVER OIL SEAL  . Refer to REMOVAL - Step 11
  26. SET NO. 1 CYLINDER TO TDC/COMPRESSION  See step  11
  27. REMOVE TIMING CHAIN GUIDE  See step  12
  28. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY  See step  13
  29. REMOVE CHAIN TENSIONER SLIPPER  See step  14
  30. REMOVE CHAIN SUB-ASSEMBLY 
  31. REMOVE NO. 1 CHAIN VIBRATION DAMPER  See step  16
  32. REMOVE CRANKSHAFT TIMING SPROCKET 
    1. Remove the crankshaft timing sprocket from the crankshaft.
      Fig 11: Identifying Crankshaft Timing Sprocket
      GTY314227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY  See step  17
  34. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY  See step  18
  35. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY  See step  19
  36. REMOVE CAMSHAFT BEARING CAP  See step  20
  37. REMOVE OIL CONTROL VALVE FILTER 
    1. Remove the oil control valve filter from the No. 1 camshaft bearing cap.
      Fig 12: Identifying Oil Control Valve Filter
      GTY179582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE CAMSHAFT  See step  23
  39. REMOVE NO. 1 CAMSHAFT BEARING 
    1. Remove the No. 1 camshaft bearing.
      Fig 13: Identifying No. 1 Camshaft Bearing
      GTY195088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE NO. 2 CAMSHAFT BEARING 
    1. Remove the No. 2 camshaft bearing.
      Fig 14: Identifying No. 2 Camshaft Bearing
      GTY195089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE CAMSHAFT HOUSING STUD BOLT 
    NOTE:

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

  42. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN 
    NOTE:

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

  43. REMOVE CAMSHAFT HOUSING STRAIGHT PIN 
    NOTE:

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

  44. REMOVE VALVE ROCKER ARM SUB-ASSEMBLY  See step  25
  45. REMOVE VALVE LASH ADJUSTER ASSEMBLY  See step  26
  46. REMOVE VALVE STEM CAP  See step  27
  47. REMOVE CYLINDER HEAD SUB-ASSEMBLY  See step  28
  48. REMOVE CYLINDER HEAD GASKET  See step  29
  49. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    1. Remove the cylinder block water jacket spacer from the cylinder block.
      Fig 15: Identifying Cylinder Block Water Jacket Spacer
      GTY312332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

  50. REMOVE OIL FILTER ELEMENT  . Refer to REPLACEMENT - Step 3
  51. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Remove the 11 bolts and 2 nuts.
      Fig 16: Location of Oil Pan Sub-Assembly Bolts And Nuts
      GTY195090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the blade of an oil pan seal cutter between the oil pan and stiffening crankcase, cut off the applied sealer and remove the oil pan.
      Fig 17: Inserting Blade Of SST Between No. 1 & No. 2 Oil Pans
      GTY192227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to damage the contact surfaces of the stiffening crankcase and oil pan.
      • Be careful not to damage the stiffening crankcase flange.
  52. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the 3 bolts, oil strainer and gasket.
      Fig 18: Location of Oil Strainer And Gasket Bolts
      GTY184315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE NO. 1 OIL PAN BAFFLE PLATE 
    1. Remove the 5 bolts and oil pan baffle plate.
      Fig 19: Location of Oil Pan Baffle Plate Bolts
      GTY190555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSPECT CRANKSHAFT BACKLASH 
    1. Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.
      Fig 20: Measuring Backlash Of Crankshaft And Balance Shaft
      GTY184440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard backlash

      0.005 to 0.020 mm (0.000197 to 0.000787 in.)

      Maximum backlash

      0.020 mm (0.000787 in.)

      If the backlash is more than the maximum, replace the engine balancer assembly.

  55. REMOVE ENGINE BALANCER ASSEMBLY 
    1. Remove the 7 bolts and engine balancer.
      Fig 21: Location of Engine Balancer Bolts
      GTY195093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not disassemble the engine balancer.

  56. INSPECT BALANCE SHAFT THRUST CLEARANCE  See step  14
  57. REMOVE STIFFENING CRANKCASE ASSEMBLY 
    1. Remove the 7 bolts.
      Fig 22: Location of Stiffening Crankcase Assembly Bolts
      GTY195095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the stiffening crankcase by prying between the stiffening crankcase and cylinder block at the places shown in the illustration.
      Fig 23: Prying Surfaces For Removing Stiffening Crankcase
      GTY310740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *A LH Side
      *B RH Side

      HINT: 

      Tape the screwdriver tip before use.

      NOTE:

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

  58. REMOVE STIFFENING CRANKCASE STUD BOLT 
    NOTE:

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

  59. REMOVE STIFFENING CRANKCASE RING PIN 
    NOTE:

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

  60. REMOVE ENGINE REAR OIL SEAL 
    1. Remove the engine rear oil seal from the cylinder block.
      Fig 24: Identifying Rear Engine Oil Seal
      GTY195097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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