Engine Unit: Disassembly

1. Remove the oil filler cap sub-assembly and oil filler gasket.

1. Remove the spark plugs.

1. Remove the oil pan drain plug and oil pan drain plug gasket.
   Fig 1: Locating Oil Pan Drain Plug

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1. Remove the ventilation valve sub-assembly.
   Fig 2: Locating Ventilation Valve Sub-Assembly

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1. Remove the 4 bolts and 4 camshaft position sensors.
   Fig 3: Locating Bolts And Camshaft Position Sensors

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1. Remove the 4 bolts and 4 camshaft oil control valves.
   Fig 4: Locating Bolts And Camshaft Oil Control Valves

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1. Remove the bolt and crankshaft position sensor.
   Fig 5: Locating Crankshaft Position Sensor

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1. Remove the 2 oil pipe unions, gaskets and oil pipe.
2. Remove the oil control valve filter LH and gaskets.
   Fig 6: Locating Oil Pipe Unions And Oil Pipe

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1. Remove the bolt.
2. Remove the 2 oil pipe unions and oil pipe.
3. Remove the oil control valve filter RH and gaskets.
   Fig 7: Locating Oil Pipe Unions And Oil Pipe

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1. Remove the cylinder block water drain cocks from the cylinder block.
2. Remove the cylinder block water drain cock plugs from the water drain cocks.
   Fig 8: Locating Cylinder Block Water Drain Cock Sub-Assembly

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1. Remove the drain plug.
   NOTE: Do not remove the O-ring from the oil filter cap.
   Fig 9: Locating Drain Plug

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2. Connect the hose to the pipe.
3. Insert the pipe with the hose into the oil filter cap.
4. Make sure that the oil is completely drained and remove the pipe and O-ring.
   Fig 10: Connecting Hose To Pipe

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5. Using SST, remove the oil filter cap sub-assembly.

   SST 09228-06501 

   Fig 11: Locating Oil Filter Cap Sub-Assembly

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6. Remove the oil filter element and 0-ring from the oil filter cap sub-assembly.
   NOTE: Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.
   Fig 12: View Of Oil Filter Element And O-Ring

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1. Using SST, loosen the crankshaft pulley bolt.

   SST 09213-70011 (09213-70020), 09330-00021 

   Fig 13: Loosening Crankshaft Pulley Bolt

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2. Using SST, remove the crankshaft pulley bolt and crankshaft pulley.

   SST 09950-50013 (09951 -05010, 09952-05010, 09953-05020, 09954-05021) 

   Fig 14: Removing Crankshaft Pulley Bolt And Crankshaft Pulley

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1. Remove the bolt, 2 clamps, and 4 clips and disconnect the 2 water by-pass hoses.
   Fig 15: Locating Bolt, Clamps, And Clips

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2. Remove the union bolt, oil cooler assembly, and O-ring.
   Fig 16: Locating Oil Cooler Union Bolt

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1. Remove the 3 bolts, 3 nuts, and oil cooler pipe with No. 1 oil cooler bracket.
   Fig 17: Locating Bolts, Nuts, And Oil Cooler Pipe With No. 1 Oil Cooler Bracket

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2. Remove the bolt, 2 nuts, No. 1 oil cooler bracket, and gasket.
3. Using a "TORX" socket wrench E8, remove the 2 stud bolts.
   Fig 18: Locating Bolt, Nuts, No. 1 Oil Cooler Bracket, And Gasket

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1. Remove the 6 bolts and No. 1 front engine mounting bracket LH.
2. Using a "TORX" socket wrench E8, remove the 2 stud bolts.
   Fig 19: Locating Engine Mounting Bracket Front And Bolts

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1. Remove the 2 nuts, water inlet and thermostat.
2. Remove the gasket.
3. Remove the drain cock plug.
4. Remove the drain cock assembly.
5. Remove the 2 stud bolts.
6. Separate the No. 1 water by-pass hose.
   Fig 20: Locating Water Inlet With Nuts

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7. Remove the 2 bolts, nut, and water inlet housing.
   Fig 21: Locating Bolts, Nut, And Water Inlet Housing

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8. Remove the 2 O-rings.
   Fig 22: Locating O-Rings

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1. Remove the 2 bolts, 4 nuts and water outlet.
   Fig 23: Locating Bolts, Nuts And Water Outlet

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2. Remove the 2 gaskets and O-ring.
   Fig 24: Locating Gaskets And O-Ring

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1. Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.
   Fig 25: Locating Bolts, Head Cover And Gasket

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2. Remove the 3 gaskets.
   Fig 26: Locating Gaskets

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1. Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.
   NOTE: The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the head cover.
   Fig 27: Locating Bolts, Seal Washer, Head Cover And Gasket

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2. Remove the 3 gaskets.
   Fig 28: Locating Gaskets

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1. Remove the 16 bolts and 2 nuts.
   Fig 29: Identifying Oil Pan With Bolts And Nuts

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2. Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

   SST 09032-00100 

   NOTE: Be careful not to damage the contact surfaces of the oil pans.
Fig 30: Inserting Blade Of SST Between Oil Pans
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a "TORX" socket wrench E6, remove the 2 stud bolts.

1. Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.
2. Using a "TORX" socket wrench E6, remove the 2 stud bolts.
   Fig 31: Identifying Oil Strainer With Bolt And Nuts

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1. Remove the 16 bolts and 2 nuts.

   HINT:

   Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

   Fig 32: Locating Bolts And Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly with a screwdriver.
   NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

   HINT:

   Tape the screwdriver tip before use.

   Fig 33: Removing Oil Pan Sub-Assembly By Prying Oil Pan Sub-Assembly

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3. Remove the 2 O-rings.
4. Using a "TORX" socket wrench E8, remove the 2 stud bolts.
   Fig 34: Locating O-Rings

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1. Remove the 7 bolts and oil pan baffle plate.
   Fig 35: Locating Oil Pan Baffle Plate Bolts

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1. Remove the 6 bolts.
   Fig 36: Locating Engine Rear Oil Seal Retainer Bolts

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2. Using a screwdriver, pry out the engine rear oil seal retainer.
   NOTE: Be careful not to damage the engine rear oil seal retainer.

   HINT:

   Tape the screwdriver tip before use.

   Fig 37: Prying Out Oil Seal Retainer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place the oil seal retainer on wooden blocks.
   NOTE: Be careful not to damage the engine rear oil seal retainer.
2. Using a screwdriver and a hammer, tap out the oil seal.

   HINT:

   Tape the screwdriver tip before use.

   Fig 38: Taping Out Oil Seal

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1. Remove the 16 bolts, water pump assembly and gasket.
   Fig 39: Locating Bolts, Water Pump And Gasket

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1. Remove the 15 bolts and 2 nuts as shown in the illustration.
   Fig 40: Locating Timing Chain Cover Bolts And Nuts

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2. Remove the timing chain cover sub-assembly by prying between the timing chain cover and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver.
   NOTE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.

   HINT:

   Tape the screwdriver tip before use.

3. Remove the 4 bolts, chain cover plate and chain cover plate gasket.
   Fig 41: Prying Between Timing Chain Cover And Cylinder Head Or Cylinder Block

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4. Remove the gasket.
   Fig 42: Locating Gasket

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1. Using a screwdriver, pry out the timing chain case oil seal.

   HINT:

   Tape the screwdriver tip before use.

1. Temporarily tighten the pulley set bolt.
   Fig 43: Prying Out Oil Seal Using Screwdriver

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC / compression).
   Fig 44: Identifying Timing Mark On Crank Angle Sensor Plate

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3. Check that the timing marks of the camshaft timing gears are aligned with those of the bearing cap as shown in the illustration.

   If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.

   Fig 45: Identifying Bearing Cap Timing Marks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
2. Move the stopper plate downward to set the lock, and insert a pin of ø 1.27 mm (0.05 in.) into the stopper plate's hole.
   Fig 46: Locating No.1 Chain Tensioner Assembly

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3. Remove the 2 bolts and No. 1 chain tensioner assembly.

1. Remove the chain tensioner slipper.
   Fig 47: Locating Chain Tensioner With Bolts

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1. Turn the crankshaft counterclockwise 10° to loosen the chain sub-assembly of the crankshaft timing sprocket.
2. Remove the pulley set bolt.
   Fig 48: Identifying Timing Mark On Crankshaft Timing Sprocket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the chain sub-assembly from the crankshaft timing sprocket and place it on the crankshaft.
   Fig 49: Identifying Chain Set

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Turn the camshaft timing gear assembly on the bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the banks.
5. Remove the chain.
   Fig 50: Identifying Camshaft Timing Gear Assembly Position

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft.
   Fig 51: Locating Idle Gear Shaft No. 2, Idle Sprocket And Idle Gear Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts and No. 1 chain vibration damper.

1. Remove the 2 No. 2 chain vibration dampers.
   Fig 52: Locating Chain Vibration Damper With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the crankshaft timing sprocket from the crankshaft.
2. Remove the 2 keys from the crankshaft.
   Fig 53: Identifying Crankshaft Timing Sprocket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. While raising the No. 2 chain tensioner assembly, insert a pin of ø 1.0 mm (0.039 in.) into the hole to fix the No. 2 chain tensioner.
   Fig 54: Inserting Pin Into Hole For Fixing No 2 Chain Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.
   NOTE:

   • Be careful not to damage the cylinder head with the wrench.
   • Do not disassemble the camshaft timing gear assemblies.
3. Remove the No. 2 chain assembly.
   Fig 55: Identifying Camshaft Timing Gear Assemblies

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and No. 2 chain tensioner assembly.
   Fig 56: Locating No.2 Chain Tensioner Bolt

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1. Check that the camshafts are positioned as shown in the illustration.
   Fig 57: Identifying Knock Pin Of Camshaft

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2. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
   Fig 58: Identifying Bearing Cap Bolts Loosening Sequence

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3. Uniformly loosen and remove the 12 bearing cap bolts in the sequence shown in the illustration.
   NOTE: Uniformly loosen the bolts while keeping the camshaft level.
Fig 59: Locating Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 5 bearing caps.

1. Remove the camshaft.

1. Remove the No. 2 camshaft.

1. Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver.
   NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

   HINT:

   Tape the screwdriver tip before use.

   Fig 60: Prying Between Cylinder Head And Camshaft Housing Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. While pushing down the No. 3 chain tensioner assembly, insert a pin of ø 1.0 mm (0.039 in.) into the hole to fix the No. 3 chain tensioner assembly.
   Fig 61: Inserting Pin Into Hole For Fixing No 3 Chain Tensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.
   NOTE:

   • Be careful not to damage the cylinder head with the wrench.
   • Do not disassemble the camshaft timing gear assemblies.
3. Remove the No. 2 chain sub-assembly.
   Fig 62: Identifying Camshaft Timing Gears & No. 2 Chain (For Bank 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and No. 3 chain tensioner assembly.
   Fig 63: Identifying No.3 Chain Tensioner Bolt

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1. Check that the camshafts are positioned as shown in the illustration.
   Fig 64: Identifying Knock Pin Of Camshaft

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2. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
   Fig 65: Identifying Bearing Cap Bolts Loosening Sequence

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3. Uniformly loosen and remove, the 13 bearing cap bolts in the sequence shown in the illustration.
   NOTE: Uniformly loosen the bolts while keeping the camshaft level.
Fig 66: Locating Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 5 bearing caps.

1. Remove the No. 3 camshaft.

1. Remove the No. 4 camshaft.

1. Remove the camshaft housing sub-assembly LH by prying between the cylinder head and camshaft housing sub-assembly LH with a screwdriver.
   NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

   HINT:

   Tape the screwdriver tip before use.

Fig 67: Prying Between Cylinder Head And Camshaft Housing
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1. Remove the 24 No. 1 valve rocker arm sub-assemblies.

   HINT:

   Arrange the removed parts in the correct order.

1. Remove the 24 valve lash adjuster assemblies from the cylinder head.

   HINT:

   Arrange the removed parts in the correct order.

1. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
   NOTE:

   • Be careful not to drop washers into the cylinder head.
   • Cylinder head warpage or cracking could result from removing bolts in an incorrect order.

   HINT:

   Be sure to keep separate the removed parts for each installation position.

2. Remove the cylinder head sub-assembly RH and cylinder head gasket.
   Fig 68: Locating Cylinder Head Bolts And Plate Washers

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1. Uniformly loosen and remove the cylinder head set bolts in the sequence shown in the illustration.
   Fig 69: Identifying Bolts In Sequence

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2. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
   NOTE:

   • Be careful not to drop washers into the cylinder head.
   • Cylinder head warpage or cracking could result from removing bolts in an incorrect order.
     Fig 70: Locating Cylinder Head Bolts And Plate Washers

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   Be sure to keep separate the removed parts for each installation position.

3. Remove the cylinder head sub-assembly LH and No. 2 cylinder head gasket.

1. Remove 2 clamps and separate the No. 1 water bypass hose.
2. Remove the 2 bolts and water inlet pipe.
Fig 71: Locating Bolts And Water Inlet Pipe
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1. Remove the valve stem caps from the cylinder heads.

   HINT:

   Arrange the removed parts in the correct order.

1. Using SST, compress the inner compression spring and remove the valve spring retainer locks.

   SST 09202-70020 (09202-00010) 

2. Remove the valve spring retainer, inner compression spring and intake valve.

   HINT:

   Arrange the removed parts in the correct order.

   Fig 72: Using SST To Compress Inner Compression Spring To Remove Intake Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, compress the inner compression spring and remove the valve spring retainer locks.

   SST 09202-70020 (09202-00010) 

2. Remove the valve spring retainer, inner compression spring and exhaust valve.

   HINT:

   Arrange the removed parts in the correct order.

   Fig 73: Using SST To Compress Inner Compression Spring To Remove Exhaust Valve

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1. Using needle-nose pliers, remove the valve stem oil seals.
   Fig 74: Removing Valve Stem Oil Seal Using Needle-Nose Pliers

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1. Using compressed air and a magnetic finger, remove the valve spring seats by blowing air onto them.
   Fig 75: Identifying Valve Spring Seat

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1. Using a 10 mm hexagon wrench, remove the 4 No. 1 straight screw plugs and 4 gaskets.
   NOTE: If water leaks from the straight screw plug or the plug corrodes, replace it.
   Fig 76: Locating No. 1 Straight Screw Plugs And Gaskets

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1. Using a 14 mm hexagon wrench, remove the 2 No. 2 straight screw plugs and 2 gaskets.
   NOTE: If water leaks from the straight screw plug or the plug corrodes, replace it.
Fig 77: Locating No. 2 Straight Screw Plugs And Gaskets
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1. Heat the cylinder head to 80 to 100°C (176 to 212°F).
2. Place the cylinder head on wooden blocks.
3. Using SST and a hammer, tap out the intake valve guide bushes.

   SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) 

Fig 78: Tapping Out Intake Valve Guide Bushes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Heat the cylinder head to 80 to 100°C (176 to 212°F).
2. Place the cylinder head on wooden blocks.
3. Using SST and a hammer, tap out the exhaust valve guide bushes.

   SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) 

Fig 79: Tapping Exhaust Valve Guide Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned.

   HINT:

   The matchmarks on the connecting rod sub-assembly and connecting rod cap are for ensuring the correct reassembly.

2. Remove the 2 connecting rod cap bolts.
   Fig 80: Locating Connecting Rod Cap Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

   HINT:

   Keep the lower bearing inserted to the connecting rod cap.

   Fig 81: Locating Connecting Rod Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a ridge reamer, remove all the carbon from the top of the cylinder.
Fig 82: Removing Carbon From Top Of Cylinder
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. 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.

HINT:

Arrange the removed parts in the correct order.

1. Uniformly loosen and remove the 8 crankshaft bearing cap bolts and seal washers in several steps and in the sequence shown in the illustration.
   Fig 83: Locating Connecting Rod Bearing Cap Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen the 16 crankshaft bearing cap bolts, in several steps and in the sequence shown in the illustration.
   Fig 84: Identifying Bearing Cap Bolts Loosening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, pry out the main bearing caps. Remove the 4 crankshaft bearing caps and lower crankshaft bearings.
   NOTE:

   • Push up on the cap little by little, from the right and left side alternately so that the cap can be removed.
   • Be careful not to damage the joint surface of the cylinder block and the main bearing cap.
   Fig 85: Identifying Bearing Caps And Lower Bearings
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the crankshaft.

1. Remove the upper crankshaft bearing and lower crankshaft bearing.

   HINT:

   Arrange the removed parts in the correct order.

1. Remove the upper crankshaft bearings and upper crankshaft thrust washers from the cylinder block sub-assembly.
   Fig 86: Identifying Upper Bearings & Upper Thrust Washers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the oil ring expander and 2 side rails by hand.

   HINT:

   Arrange the removed parts in the correct order.

   Fig 87: Identifying Compression Rings

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1. Check the fitting condition between the piston and piston pin.
   1. Try to move the piston back and forth on the piston pin.

      If any movement is felt, replace the piston and pin as a set.

      Fig 88: Checking Fitting Condition Between Piston And Piston Pin

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the connecting rod from the piston.
   1. Using a screwdriver, pry off the piston pin hole snap rings from the piston.
      Fig 89: Prying Off Snap Rings From Piston

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Gradually heat the piston to approximately 80°C(176°F).
      Fig 90: Heating Piston

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   3. Using a brass bar and plastic hammer, lightly tap out the piston pin and remove the connecting rod.

      HINT:

      • The piston and pin are a matched set.
      • Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
        Fig 91: Prying Off Snap Rings From Piston

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a gasket scraper, remove the carbon from the piston top.
   Fig 92: Removing Carbon From Piston Top

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
   Fig 93: Cleaning Piston Ring Grooves

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5. Using solvent and a brush, thoroughly clean the piston.
   NOTE: Do not use a wire brush.
   Fig 94: Cleaning Piston Using Solvent And Brush

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1. Using a 5 mm hexagon wrench, remove the bolts and No. 1 oil nozzle sub-assembly.
2. Check the 3 oil nozzles for damage or clogging. If necessary, replace the No. 1 oil nozzle sub-assembly.
Fig 95: Identifying Bolt And Oil Nozzle
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