Engine Unit: Disassembly

REMOVE OIL FILLER CAP SUB-ASSEMBLY
1. Remove the oil filler cap from the cylinder head cover.
  
  Fig 1: Removing Oil Filler Cap From Cylinder Head Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL FILLER CAP GASKET
1. Using a screwdriver, remove the gasket from the oil filler cap.
  
  Fig 2: Removing Gasket From Oil Filler Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VENTILATION VALVE SUB-ASSEMBLY
1. Remove the ventilation valve from the cylinder head cover.
  
  Fig 3: Identifying Ventilation Valve And Cylinder Head Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPARK PLUG
1. Using a spark plug wrench, remove the 4 spark plugs.
  
  Fig 4: Removing Spark Plugs Using Spark Plug Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
1. Remove the 9 bolts, 2 seal washers and 2 nuts, then remove the cylinder head cover.
  
  Fig 5: Removing Cylinder Head Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER GASKET
1. Remove the gasket from the cylinder head cover.
  
  Fig 6: Removing Gasket From Cylinder Head Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE MOUNTING BRACKET RH
1. Remove the 3 bolts, then remove the engine mounting bracket RH.
  
  Fig 7: Removing Engine Mounting Bracket RH With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER PUMP ASSEMBLY
1. Remove the 6 bolts, then remove the water pump.
  
  Fig 8: Removing Bolts And Water Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER PUMP O-RING
1. Remove the O-ring from the timing chain cover.
  
  Fig 9: Removing O-Ring From Timing Chain Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT PULLEY
1. Set the No. 1 cylinder to the TDC/compression.
  1. Turn the crankshaft pulley until its groove and timing mark "0" of the timing chain cover are aligned.
  2. Check that the point marks of the camshaft timing gears are in a straight line on the timing chain cover surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the marks as above.
    
    Fig 10: Locating Point Marks Of Camshaft Timing Gears
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the crankshaft pulley bolt.
  SST 09960-10010 (09962-01000, 09963-01000)
3. Remove the crankshaft pulley from the crankshaft.
  
  Fig 11: Removing Crankshaft Pulley Bolt AND SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CHAIN TENSIONER ASSEMBLY NO.1
1. Remove the 2 nuts, then remove the chain tensioner.
  
  Fig 12: Removing Oil Strainer With Nuts And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
1. Remove the 10 bolts and 2 nuts.
2. Remove the timing chain cover by prying the portions between the timing chain cover, cylinder head and cylinder block with a screwdriver.
  NOTE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.
  
  Fig 13: Removing Timing Chain Or Belt Cover Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a "TORX" socket wrench E5, remove the 3 stud bolts.
  
  Fig 14: Removing Stud Bolts Using "Torx" Socket Wrench E5
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TIMING CHAIN OR BELT COVER OIL SEAL
1. Place the timing chain cover on wooden blocks.
2. Using a screwdriver, remove the oil seal.
  
  Fig 15: Removing Timing Chain Or Belt Cover Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
1. Remove the crankshaft position sensor plate from the crankshaft.
  
  Fig 16: Removing Crankshaft Position Sensor Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CHAIN TENSIONER SLIPPER
1. Remove the bolt, then remove the chain tensioner slipper.
  
  Fig 17: Locating Chain Tensioner Slipper With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CHAIN SUB-ASSEMBLY
1. Using 2 screwdrivers, pry out the chain with the crankshaft timing gear, as shown in the illustration.
  NOTE:
  - Use a shop rag to protect the engine.
  - If revolving the camshafts with the chain off the gears, turn the crankshaft 1/4 revolution to prevent the valves from coming into contact with the pistons.
    
    Fig 18: Removing Chain Sub-Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CHAIN VIBRATION DAMPER NO.1
1. Remove the 2 bolts, then remove the chain vibration damper.
  
  Fig 19: Removing Chain Vibration Damper With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PUMP ASSEMBLY
1. Remove the 5 bolts, then remove the oil pump.
  
  Fig 20: Removing Oil Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PUMP GASKET
1. Remove the gasket from the cylinder block.
  
  Fig 21: Removing Gasket From Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Remove the bolt, then remove the camshaft timing oil control valve.
  
  Fig 22: Removing Camshaft Timing Oil Control Valve With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL CONTROL VALVE FILTER
1. Remove the bolt together with the gasket and oil control valve filter.
2. Remove the gasket and oil control valve filter from the bolt.
  
  Fig 23: Removing Gasket And Oil Control Valve Filter From Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT
1. Using several steps, uniformly loosen and remove the 19 bearing cap bolts in the sequence shown in the illustration.
2. Remove the 9 bearing caps, then remove the 2 camshafts from the cylinder head.
REMOVE CAMSHAFT TIMING GEAR OR SPROCKET
1. Clamp the camshaft in a vise, then remove the bolt and camshaft timing gear.
  NOTE: Be careful not to damage the camshaft.
  
  Fig 25: Removing Camshaft Timing Gear Or Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
1. Check the lock of the camshaft timing gear.
  1. Clamp the camshaft in a vise, then confirm that the camshaft timing gear is locked.
    NOTE: Be careful not to damage the camshaft.
2. Release the lock pin.
  1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
    HINT:
    
    Two advance side paths are provided in the groove of the camshaft. Plug one of the paths with a piece of rubber.
  2. Puncture the tape over the advance side path and retard side path on the opposite side of the groove.
  3. Apply air pressure to the two broken paths (the advance side path and retard side path) of about 150 kPa (1.5 kgf/cm² ).
    CAUTION: Cover the paths with a shop rag to avoid oil splashes.
    
    Fig 27: Applying Air Pressure Advance Side Path And Retard Side Path
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Confirm that the camshaft timing gear revolves in the timing advance direction when weakening the air pressure of the timing retard path.
    HINT:
    
    The lock pin is released, and the camshaft timing gear revolves in the advance direction.
    
    Fig 28: Checking Camshaft Timing Gear Revolves In Timing Advance Direction
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. When the camshaft timing gear comes to the most advanced position, release the air pressure of the timing retard side path, then release that of the timing advance side path.
    CAUTION: The camshaft timing gear occasionally shifts to the retard side abruptly if the air compression of the advance side path is released before the retard side path. This often causes the breakage of the lock pin.
3. Check the smooth revolution.
  1. Revolve the camshaft timing gear several times within the movable range except for the most retarded position and check that it turns smoothly.
    CAUTION: Be sure to perform this check by hand, instead of using air pressure.
4. Check that the lock is in the most retarded position.
  1. Confirm that the camshaft timing gear is locked in the most retarded position.
REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
1. Clamp the camshaft in a vise, then confirm that the camshaft timing gear is locked.
  CAUTION: Be careful not to damage the camshaft.
  
  Fig 29: Checking Lock Of Camshaft Timing Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
  HINT:
  
  Two advance side paths are provided in the groove of the camshaft. Plug one of the paths with a piece of rubber.
3. Puncture the tape over the advance side path and retard side path on the opposite side of the groove.
4. Apply air pressure to the two broken paths (the advance side path and retard side path) of about 150 kPa(1.5 kgf/cm² ).
  CAUTION: Cover the paths with a shop rag to avoid oil splashes.
  
  Fig 30: Applying Air Pressure To Broken Paths
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Confirm that the camshaft timing gear revolves in the timing advance direction when weakening the air pressure of the timing retard path.
  HINT:
  
  The lock pin is released, and the camshaft timing gear revolves in the advance direction.
  
  Fig 31: Identifying Camshaft Timing Gear Revolves In Timing Advance Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. When the camshaft timing gear comes to the most advanced position, release the air pressure of the timing retard side path, then release that of the timing advance side path.
  CAUTION: The camshaft timing gear occasionally shifts to the retard side abruptly if the air compression of the advance side path is released before the retard side path. This often causes the breakage of the lock pin.
7. Remove the fringe bolt and camshaft timing gear.
  NOTE:
  - Be sure not to remove the other 4 bolts.
  - When reusing the camshaft timing gear, release the straight pin locking first, then install the gear.
    
    Fig 32: Removing Fringe Bolt And Camshaft Timing Gear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD SUB-ASSEMBLY
1. Using several steps, uniformly loosen and remove the 10 cylinder head bolts with a bi-hexagon wrench 10 mm in the sequence shown in the illustration. Remove the 10 cylinder head bolts and 10 plate washers.
  NOTE:
  - Be careful not to drop the plate washers into the cylinder head.
  - Head warpage or cracking could result from removing the bolts in the wrong order.
  Fig 33: Identifying Cylinder Head Bolt Loosen Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the cylinder head from the cylinder block.
  
  Fig 34: Removing Cylinder Head From Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD GASKET
1. Remove the cylinder head gasket from the cylinder block.
  
  Fig 35: Removing Cylinder Head Gasket From Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL FILTER SUB-ASSEMBLY
1. Using SST, remove the oil filter.
  SST 09228-06501
  
  Fig 36: Removing Oil Filter Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL FILTER UNION
1. Using a socket hexagon wrench 12, remove the oil filter union.
  
  Fig 37: Removing Oil Filter Union Using Socket Hexagon Wrench 12
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE REAR OIL SEAL
1. Using a knife, cut off the oil seal lip.
2. Using a screwdriver with its tip wrapped with tape, pry out the oil seal.
  NOTE: After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.
  
  Fig 38: Removing Engine Rear Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PAN DRAIN PLUG
1. Remove the oil pan drain plug and gasket from the oil pan.
  
  Fig 39: Removing Oil Pan Drain Plug And Gasket From Oil Pan
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PAN SUB-ASSEMBLY
1. Remove the 14 bolts and 2 nuts.
  
  Fig 40: Removing Oil Pan With Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Insert the blade of SST between the bearing cap and oil pan, then cut off the applied sealer and remove the oil pan.
  SST 09032-00100
  
  NOTE: Be careful not to damage the oil pan contact surface of the bearing cap and oil pan.
  
  Fig 41: Inserting Blade Of SST Between Bearing Cap And Oil Pan
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL STRAINER SUB-ASSEMBLY
1. Remove the bolt and 2 nuts, then remove the oil strainer.
  
  Fig 42: Removing Oil Strainer With Nuts And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL STRAINER FLANGE GASKET
1. Remove the gasket from the cylinder block.
  
  Fig 43: Removing Gasket From Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Remove the cylinder block water drain cock from the cylinder block.
  
  Fig 44: Removing Cylinder Block Water Drain Cock From Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK CONNECTING ROD THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
  Standard thrust clearance:
  
  0.160 to 0.342 mm (0.0063 to 0.0135 in.)
  
  Maximum thrust clearance:
  
  0.342 mm (0.0135 in.)
  - If the thrust clearance is greater than maximum, replace the connecting rod.
  - If necessary, replace the crankshaft.
    
    Fig 45: Measuring Thrust Clearance
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

CHECK CONNECTING ROD OIL CLEARANCE

NOTE: Do not turn the crankshaft during the measurement.

Using marking paint, write the matched cylinder number on each connecting rod and cap.
HINT:

The matchmarks on the connecting rods and caps are for ensuring the correct reassembly.

Fig 46: Identifying Matchmarks On Connecting Rods And Caps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST, remove the 2 bolts and connecting rod cap.
SST 09205-16010

Fig 47: Removing Bolts And Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Clean the crank pin and bearing.
Check the crank pin and bearing for pitting and scratches.
Lay a strip of the Plastigage across the crank pin.

Fig 48: Laying Strip Of Plastigage Across Crank Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check that the front mark of the connecting rod cap is facing in the correct direction.
Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.

Fig 49: Aligning Pin Dowels Of Connecting Rod Cap With Pins Of Connecting Rod
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST, tighten the bolts in several passes to the specified torque.
SST 09205-16010

Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)

Fig 50: Removing Bolts And Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Mark the front of the connecting cap bolts with paint.
Retighten the cap bolts by 90° as shown in the illustration.
Check that the crankshaft turns smoothly.

Fig 51: Checking Paint Mark On Connecting Rod Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the 2 bolts and connecting rod cap.

Fig 52: Removing Bolts And Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Measure the Plastigage at its widest point.

Standard oil clearance:

0.028 to 0.060 mm (0.0011 to 0.0024 in.)

Maximum oil clearance:

0.080 mm (0.0032 in.)

NOTE: Remove the Plastigage completely after the measurement.

If the oil clearance is greater than maximum, replace the connecting rod bearing.
If necessary, grind or replace the crankshaft.

Fig 53: Measuring Plastigage At Widest Point
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 54: Identifying TAIHO Mark On Claw Side Or Opposite Side
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

The TAIHO mark is either on the claw side or the opposite side.

If replacing a bearing, select a new one with the same number as marked on the connecting rod bearing cap. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.

TAIHO MARK SPECIFICATION

Item	Mark	mm (in.)
Connecting rod large end bore diameter	1	47.000 to 47.008 (1.8504 to 1.8507)
	2	47.009 to 47.016 (1.8507 to 1.8510)
	3	47.017 to 47.024 (1.8511 to 1.8513)
Connecting rod bearing thickness	1	1.486 to 1.490 (0.0585 to 0.0587)
	2	1.491 to 1.494 (0.0587 to 0.0588)
	3	1.495 to 1.498 (0.0589 to 0.0590)
Crankshaft pin outer diameter	-	43.992 to 44.000 (1.7320 to 1.7323)

REMOVE CONNECTING ROD SUB-ASSEMBLY
1. Using a ridge reamer, remove all carbon from the top of the cylinder.
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
  HINT:
  - Keep the bearing, connecting rod and cap together.
  - Arrange the piston and connecting rod assemblies in the correct order.
    
    Fig 55: Removing All Carbon From Top Of Cylinder Using Ridge Reamer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONNECTING ROD BEARING
1. Remove the connecting rod bearing from the connecting rod cap.
  
  Fig 56: Removing Connecting Rod Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the connecting rod bearing from the connecting rod.
  
  Fig 57: Identifying Connecting Rod Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON RING SET
1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the 2 side rails and oil ring by hand.
  
  Fig 58: Removing Piston Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE W/PIN PISTON SUB-ASSEMBLY
1. Using a small screwdriver, pry out the 2 snap rings.
  
  Fig 59: Removing Snap Ring Onto Other End Of Piston Pin Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Gradually heat the piston up to 80 to 90°C (176 to 194°F).
  
  Fig 60: Heating Piston Up To 80 To 90°C (176 To 194°F)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic hammer and brass bar, lightly tap out the piston pin, then remove the connecting rod.
  HINT:
  - The piston and pin are a matched set.
  - Arrange the piston, pin, ring, connecting rod and bearings in the correct order.
    
    Fig 61: Removing Connecting Rod
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT
1. Remove the 10 bolts from the crankshaft bearing cap.
  
  Fig 62: Removing Bolts From Crankshaft Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen the 10 bearing cap bolts in several passes in the sequence shown in the illustration.
  
  Fig 63: Identifying Bearing Cap Bolts Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, remove the crankshaft bearing cap by prying the indicated portions between the cylinder block and crankshaft bearing cap.
  NOTE: Be careful not to damage the contact surfaces of the cylinder block and crankshaft bearing cap.
  
  Fig 64: Removing Crankshaft Bearing Cap By Prying Indicated Portions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the crankshaft from the cylinder block.
  
  Fig 65: Removing Crankshaft From Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK CRANKSHAFT THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
  Standard thrust clearance:
  
  0.04 to 0.24 mm (0.0016 to 0.0094 in.)
  
  Maximum thrust clearance:
  
  0.30 mm (0.0118 in.)
  - If the thrust clearance is greater than maximum, measure the thrust washer thickness.
  - If the thickness is not as specified, replace the thrust washer.
    
    Fig 66: Measuring Thrust Clearance
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  HINT:
  
  Thrust washer thickness: 2.430 to 2.480 mm (0.0957 to 0.0976 in.).
REMOVE CRANKSHAFT THRUST WASHER UPPER
1. Remove the 2 crankshaft thrust washers from the cylinder block.
  
  Fig 67: Removing Crankshaft Thrust Washers From Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT BEARING
1. Remove the 5 crankshaft bearings from the cylinder block.
  NOTE: Arrange the main bearings and thrust washers in the correct order.
  
  Fig 68: Removing Crankshaft Bearings From Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 5 crankshaft bearings from the bearing caps.
  NOTE: Arrange the main bearings and thrust washers in the correct order.
REMOVE STUD BOLT
1. Using "TORX" socket wrenches E5 and E7, remove the 9 stud bolts.
  
  Fig 70: Locating Stud Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002