Engine Unit: Disassembly: Disassembly

WARNING: This page is about a different car, the 2010 Toyota FJ Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

Fig 1: Identifying Engine Oil Pressure Switch
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a 24 mm deep socket wrench, remove the oil pressure switch.
REMOVE ENGINE COOLANT TEMPERATURE SENSOR

Fig 2: Identifying Engine Coolant Temperature Sensor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a 19 mm deep socket wrench, remove the sensor.
2. Remove the gasket from the sensor.
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

Fig 3: Identifying Cylinder Block Water Drain Cock Plugs
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 water drain cock plugs from the water drain cocks.
2. Remove the 2 water drain cocks from the cylinder block.
REMOVE VVT SENSOR

Fig 4: Identifying VVT Sensor And Bolts (LH)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. LH:
  Remove the 2 bolts and 2 VVT sensors.
2. RH:
  
  Fig 5: Identifying VVT Sensor And Bolts (RH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Remove the 2 bolts and 2 VVT sensors.
REMOVE CRANKSHAFT POSITION SENSOR

Fig 6: Identifying Crankshaft Position Sensor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the bolt and crankshaft position sensor.
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

Fig 7: Identifying Camshaft Timing Oil Control Valve Assembly LH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. LH:
  Remove the 2 bolts and 2 oil control valves.
2. RH:
  
  Fig 8: Identifying Camshaft Timing Oil Control Valve Assembly RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Remove the 2 bolts and 2 oil control valves.
REMOVE OIL FILLER CAP HOUSING

Fig 9: Identifying Oil Filler Cap Housing, Gasket And Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the oil filler cap.
2. Remove the 2 nuts, oil filler cap housing and gasket.
REMOVE NO. 1 OIL PIPE . Refer to REMOVAL - Step 10
REMOVE NO. 2 OIL PIPE . Refer to REMOVAL - Step 11
REMOVE OIL FILTER ELEMENT . Refer to REPLACEMENT - Step 4
REMOVE OIL FILTER BRACKET . Refer to REMOVAL - Step 8
REMOVE WATER INLET HOUSING . Refer to REMOVAL - Step 4
REMOVE REAR WATER BY-PASS JOINT

Fig 10: Removing Water By-Pass Joint, Bolts & Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 bolts, 4 nuts, rear water by-pass joint and 2 gaskets.
2. Remove the O-ring from the No. 1 water outlet pipe.
REMOVE SPARK PLUG . Refer to REMOVAL - Step 4
REMOVE VENTILATION VALVE SUB-ASSEMBLY
1. Remove the ventilation valve hose.
2. Remove the ventilation valve.
  
  Fig 11: Identifying Ventilation Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT PULLEY . Refer to REMOVAL - Step 9
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

Fig 12: Identifying Cylinder Head Cover Sub-Assembly And Bolts (LH)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 12 bolts, seal washer, cylinder head cover and gasket.
  HINT:
  
  Make sure the removed parts are returned to the same places they were removed from.
2. Remove the 3 gaskets.
  
  Fig 13: Identifying Gaskets (LH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH

Fig 14: Identifying Cylinder Head Cover Sub-Assembly And Bolts (RH)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 12 bolts, seal washer, cylinder head cover and gasket.
  HINT:
  
  Make sure the removed parts are returned to the same places they were removed from.
2. Remove the 3 gaskets.
  
  Fig 15: Identifying Gaskets (RH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPARK PLUG TUBE GASKET

Fig 16: Identifying Spark Plug Tube Gasket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Bend the ventilation baffle plate claws on the cylinder head cover to an angle of 90° or more.
  TEXT IN ILLUSTRATION
  
  *a Pry
2. Remove the 6 spark plug tube gaskets.
  NOTE:
  Be careful not to damage the gasket when removing it, as the removed gasket needs to be used when installing a new one.
REMOVE OIL PAN DRAIN PLUG
1. Remove the drain plug and gasket.
REMOVE NO. 2 OIL PAN SUB-ASSEMBLY . Refer to REMOVAL - Step 16
REMOVE OIL STRAINER SUB-ASSEMBLY . Refer to REMOVAL - Step 17
REMOVE OIL PAN SUB-ASSEMBLY . Refer to REMOVAL - Step 18
REMOVE NO. 1 OIL PAN BAFFLE PLATE

Fig 17: Identifying No. 1 Oil Pan Baffle Plate And Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 6 bolts and No. 1 oil pan baffle plate.
REMOVE ENGINE REAR OIL SEAL RETAINER

Fig 18: Identifying Engine Rear Oil Seal Retainer, Bolts And Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 5 bolts and 2 nuts.
2. Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and crankshaft bearing cap.
  TEXT IN ILLUSTRATION
  
  *a Pry
  
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE REAR CRANKSHAFT OIL SEAL

Fig 19: Tapping Out Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a screwdriver and hammer, tap out the oil seal.
  NOTE:
  Be careful not to damage the rear oil seal retainer.
REMOVE TIMING CHAIN COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 19
REMOVE WATER PUMP ASSEMBLY

Fig 20: Identifying Water Pump Assembly And Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 8 bolts, water pump and gasket.
REMOVE FRONT CRANKSHAFT OIL SEAL . Refer to REMOVAL - Step 20

SET NO. 1 CYLINDER TO TDC / COMPRESSION

Temporarily tighten the pulley set bolt.

Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression).

Fig 21: Identifying Timing Mark On The Crank Angle Sensor Plate

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Center Line
*2	Timing Mark
*3	Sensor Plate

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

Fig 22: Checking Alignment Of Camshaft Timing Gears And Bearing Caps Timing Marks
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

*1 Timing Mark

REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

Fig 23: Identifying No. 1 Chain Tensioner Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

TEXT IN ILLUSTRATION

*1	Plunger
*2	Stopper Plate
*3	Pin

Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm (0.0500 in.) into the stopper plate hole.
Remove the 2 bolts and No. 1 chain tensioner assembly.

Fig 24: Identifying No. 1 Chain Tensioner Assembly And Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE CHAIN TENSIONER SLIPPER

Fig 25: Identifying Chain Tensioner Slipper
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the chain tensioner slipper.

REMOVE CHAIN SUB-ASSEMBLY

Fig 26: Turning Crankshaft Counterclockwise 10° To Loosen Chain Of Crankshaft Timing Sprocket

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket.

TEXT IN ILLUSTRATION

*1	Center Line
*2	Timing Mark
*3	Sensor Plate

Remove the pulley set bolt.
Remove the chain sub-assembly from the crankshaft timing sprocket and place it on the crankshaft.

Fig 27: Identifying Crankshaft Timing Sprocket And Chain
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Turn the camshaft timing gear assembly on bank 1 clockwise approximately 60° so that it is as shown in the illustration. Be sure to loosen the chain subassembly between the banks.

Fig 28: Turning Camshaft Timing Gear Assembly On Bank 1 Clockwise Approximately 60°
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the chain sub-assembly.
TEXT IN ILLUSTRATION

*a Bank 1:

REMOVE NO. 1 IDLE GEAR SHAFT

Fig 29: Identifying No. 1 Idle Gear Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, No. 1 idle gear and No. 1 idle gear shaft.
REMOVE NO. 1 CHAIN VIBRATION DAMPER

Fig 30: Identifying No. 1 Chain Vibration Damper And Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 bolts and No. 1 chain vibration damper.
REMOVE NO. 2 CHAIN VIBRATION DAMPER

Fig 31: Identifying No. 2 Chain Vibration Damper
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 No. 2 chain vibration dampers.
REMOVE CRANKSHAFT TIMING SPROCKET

Fig 32: Identifying Crankshaft Timing Sprocket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the crankshaft timing sprocket.

REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

Fig 33: Identifying Camshaft Timing Gears And No. 2 Chain (Bank 1)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

While raising the No. 2 chain tensioner assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to hold the No. 2 chain tensioner assembly.

TEXT IN ILLUSTRATION

*1	Pin
*2	Plunger
*a	Push

Using SST to hold the hexagonal portion of each camshaft, loosen the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

Fig 34: Identifying Camshaft Timing Gear Assembly, Camshaft Timing Exhaust Gear Assembly, SST And Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*a	Turn
*b	Hold

SST: 09922-10010

NOTE:

Do not loosen the other 4 bolts. If any of the 4 bolts is loosened, replace the camshaft timing gear assembly and/or camshaft timing exhaust gear assembly with a new one.

Remove the 2 bolts and the camshaft timing gear assembly together with the No. 2 chain.

REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

Fig 35: Identifying No. 2 Chain Tensioner Assembly And Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the bolt and No. 2 chain tensioner assembly.

REMOVE CAMSHAFT BEARING CAP (for Bank 1)

Fig 36: Identifying Camshaft Bearing Cap (Bank 1)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check that the camshafts are positioned as shown in the illustration.

TEXT IN ILLUSTRATION

*1	Knock Pin
*a	Front View

Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration.

Fig 37: Identifying Bearing Cap Bolt Loosening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Uniformly loosen and remove the 12 bearing cap bolts in several steps in the sequence shown in the illustration.

Fig 38: Identifying Bearing Cap Bolt Loosening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:
Uniformly loosen the bolts while keeping the camshaft level.
Remove the 5 camshaft bearing caps.
Remove the camshaft and No. 2 camshaft.

REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

Fig 39: Identifying Camshaft Housing Sub-Assembly RH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver.
  TEXT IN ILLUSTRATION
  
  *1 Protective Tape
  
  NOTE:
  Be careful not to damage the contact surfaces of the cylinder head and camshaft housing sub-assembly RH.
  
  HINT:
  
  Tape the screwdriver tip before use.

REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

Fig 40: Identifying No. 3 Chain Tensioner Assembly And Pin

While pushing down the No. 3 chain tensioner assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to hold the No. 3 chain tensioner assembly.

TEXT IN ILLUSTRATION

*1	Pin
*2	Plunger
*a	Push

Using SST to hold the hexagonal portion of each camshaft, loosen the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

Fig 41: Identifying Camshaft Timing Gear Assembly, Camshaft Timing Exhaust Gear Assembly, SST And Bolts

TEXT IN ILLUSTRATION

*a	Turn
*b	Hold

SST: 09922-10010

NOTE:

Do not loosen the other 4 bolts. If any of the 4 bolts is loosened, replace the camshaft timing gear assembly and/or camshaft timing exhaust gear assembly with a new one.

Remove the 2 bolts and the camshaft timing gear together with the No. 2 chain.

REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

Fig 42: Identifying No. 3 Chain Tensioner Assembly And Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the bolt and No. 3 chain tensioner assembly.

REMOVE CAMSHAFT BEARING CAP (for Bank 2)

Fig 43: Identifying Camshaft Bearing Cap (Bank 2)

Check that the camshafts are positioned as shown in the illustration.

TEXT IN ILLUSTRATION

*1	Knock Pin
*a	Front View

Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration.

Fig 44: Identifying Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Uniformly loosen and remove the 13 bearing cap bolts in several steps and in the sequence shown in the illustration.

Fig 45: Identifying Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:
Uniformly loosen the bolts while keeping the camshaft level.
Remove the 5 camshaft bearing caps.
Remove the No. 3 camshaft and No. 4 camshaft.

REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

Fig 46: Identifying Camshaft Housing Sub-Assembly LH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the camshaft housing sub-assembly LH by prying between the cylinder head and camshaft housing sub-assembly LH with a screwdriver.
  TEXT IN ILLUSTRATION
  
  *1 Protective Tape
  
  NOTE:
  Be careful not to damage the contact surfaces of the cylinder head and camshaft housing sub-assembly LH.
  
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Remove the 24 valve rocker arms from the cylinder head.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE VALVE LASH ADJUSTER ASSEMBLY
1. Remove the 24 valve lash adjusters from the cylinder head.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE VALVE STEM CAP
1. Remove the 24 valve stem caps from the cylinder head.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE CYLINDER HEAD SUB-ASSEMBLY See step 21
REMOVE CYLINDER HEAD LH See step 22
REMOVE CYLINDER HEAD GASKET
REMOVE NO. 2 CYLINDER HEAD GASKET
REMOVE NO. 1 WATER OUTLET PIPE . Refer to REMOVAL - Step 2
REMOVE KNOCK SENSOR . Refer to REMOVAL - Step 3
REMOVE CYLINDER BLOCK WATER JACKET SPACER

Fig 47: Identifying Cylinder Block Water Jacket Spacer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 water jacket spacers from the cylinder block.
  NOTE:
  Be sure to remove the water jacket spacers. If not, they may fall and become damaged when the cylinder block is inverted.
REMOVE STRAIGHT PIN
HINT:

It is not necessary to remove the straight pin unless it is being replaced.
REMOVE RING PIN
HINT:

It is not necessary to remove the ring pin unless it is being replaced.
REMOVE STUD BOLT
HINT:

It is not necessary to remove the stud bolt unless it is being replaced.