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Engine Unit: Disassembly

WARNING: This page is about a different car, the 2008 Lexus LS 600hL. However, it is still accessible from the selected car via links, so may be relevant.

HINT

When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side.

REMOVE OIL FILLER CAP SUB-ASSEMBLY

Fig 1: Locating Ignition Coils Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL FILLER CAP HOUSING
1. Remove the 2 bolts, filler cap housing and gasket.
REMOVE SPARK PLUG (See REMOVAL )

Fig 2: Locating Oil Filler Cap Housing Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VVT SENSOR
1. for Bank 1:
  Remove the 2 bolts and 2 VVT sensors.
  
  Fig 3: Locating VVT Sensor Bolts (For Bank 1)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. for Bank 2:
  Remove the 2 bolts and 2 VVT sensors.
  
  Fig 4: Locating VVT Sensor Bolts (For Bank 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT POSITION SENSOR
1. Remove the bolt and camshaft position sensor
  
  Fig 5: Locating Camshaft Position Sensor Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT POSITION SENSOR
1. Remove the bolt and crankshaft position sensor.
  
  Fig 6: Locating Crankshaft Position Sensor Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. for Bank 1.
  Remove the bolt and oil control valve. Remove the O-ring from the valve
  
  Fig 7: Locating Camshaft Timing Oil Control Valve Bolt (For Bank 1)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. for Bank 2-
  Remove the bolt and oil control valve. Remove the O-ring from the valve.
  
  Fig 8: Locating Camshaft Timing Oil Control Valve Bolt (For Bank 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
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 CAMSHAFT TIMING CONTROL MOTOR LH (See REMOVAL )
REMOVE CAMSHAFT TIMING CONTROL MOTOR RH (See REMOVAL )

Fig 9: Locating Cylinder Block Water Drain Cocks
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WIRE HARNESS CLAMP BRACKET
1. Remove the bolt and wire harness clamp bracket.
REMOVE OIL FILTER ELEMENT (See REPLACEMENT )
REMOVE OIL FILTER BRACKET (See REMOVAL )
REMOVE WATER PUMP PULLEY (See REMOVAL )

Fig 10: Locating Wire Harness Clamp Bracket Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT WATER BY-PASS JOINT
1. Remove the 4 nuts, water by-pass joint and 2 gaskets.
  
  Fig 11: Locating Front Water By-Pass Joint Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPARK PLUG TUBE GASKET
1. Using a screwdriver, pry out the 8 plug tube gaskets.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 12: Removing Spark Plug Tube Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
1. Remove the fuel pump spacer.
2. Remove the fuel pump spacer gasket.
3. Remove the 15 bolts in the order shown in the illustration. Then remove the 2 seal washers, cylinder head cover and gasket
  HINT
  
  Make sure the removed parts are returned to the same places they were removed from.
  
  Fig 13: Locating Loosening Sequence Of Cylinder Head Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 4 gaskets and 2 O-rings from the camshaft bearing caps (No. 2, No. 3 and No. 7).
  
  Fig 14: Locating Gaskets And O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH
1. Remove the fuel pump spacer
2. Remove the fuel pump spacer gasket.
3. Remove the 15 bolts in the order shown in the illustration. Then remove the 2 seal washers, cylinder head cover and gasket.
  HINT:
  
  Make sure the removed parts are returned to the same places they were removed from.
  
  Fig 15: Locating Loosening Sequence Of Cylinder Head Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 4 gaskets and 2 O-rings from the camshaft bearing caps (No 1, No. 3 and No 6).
  
  Fig 16: Locating Gaskets And O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL CONTROL VALVE FILTER
1. for LH.
  1. Remove the 2 bolts, cylinder head cover spacer, gasket and valve filter.
    
    Fig 17: Locating Oil Control Valve Filter Bolts (For LH)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. for RH:
  1. Remove the 2 bolts, cylinder head cover spacer, "gasket and valve filter.
REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (See REMOVAL )
REMOVE CRANKSHAFT PULLEY (See REMOVAL )
REMOVE WATER PUMP (See REMOVAL )
REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (See REMOVAL )

Fig 18: Locating Oil Control Valve Filter Bolts (For RH)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER INLET PIPE (See DISASSEMBLY )
REMOVE FRONT CRANKSHAFT OIL SEAL
1. Place the timing chain cover on wooden blocks.
2. Using a screwdriver and wooden block, pry out the oil seal.
  NOTE: Do not damage the surface of the oil seal press fit hole.
  
  HINT
  
  Tape the screwdriver tip before use.
  
  Fig 19: Removing Front Crankshaft Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SET NO. 1 CYLINDER TO TDC / COMPRESSION
1. Temporarily install the crankshaft pulley bolt
2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear 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.
3. Remove the crankshaft pulley bolt.
  
  Fig 20: Identifying Timing Marks On Crankshaft Timing Gear And Camshaft Timing Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH
1. Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.
  
  Fig 21: Moving Stopper Plate Clockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.
  
  Fig 22: Moving Stopper Plate Counterclockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 bolts, chain tensioner and gasket
REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

Fig 23: Locating Chain Tensioner Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN VIBRATION DAMPER LH
Remove the 2 bolts and chain vibration damper.

Fig 24: Locating Chain Vibration Damper Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH
1. While pushing down the No 3 chain tensioner, insert a pin of Ø 1.0 mm (0.0394 in) into the hole to fix it in place
  
  Fig 25: Pushing Down Chain Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt with a 12 mm hexagon wrench.
  NOTE:
  - Be careful not to damage the cylinder head with the wrench.
  - Do not disassemble the camshaft timing gear.
    
    Fig 26: Removing Camshaft Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.
  NOTE: Be careful not to damage the cylinder head with the wrench.
4. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket LH.
5. Remove the No. 1 and No. 2 chains from the gears.
  
  Fig 27: Removing Camshaft Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
1. Remove the 2 bolts and chain tensioner.
  
  Fig 28: Locating Chain Tensioner Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH
1. Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.
  
  Fig 29: Moving Stopper Plate Clockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.
  
  Fig 30: Moving Stopper Plate Counterclockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 bolts and chain tensioner.
REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

Fig 31: Locating Chain Tensioner Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN VIBRATION DAMPER RH
1. Remove the 2 bolts and vibration damper.
  
  Fig 32: Locating Vibration Damper Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH
1. While raising up the No 2 chain tensioner, insert a pin of Ø 1.0 mm (0.0394 in.) into the hole to fix it in place
  
  Fig 33: Raising Up Chain Tensioner And Inserting Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt with a 12 mm hexagon wrench.
  NOTE:
  - Be careful not to damage the cylinder head with the wrench.
  - Do not disassemble the camshaft timing gear.
    
    Fig 34: Removing Camshaft Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.
  NOTE: Be careful not to damage the cylinder head with the wrench.
4. Remove the 2 bolts. Then with the No. 1 and No 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket RH.
5. Remove the No. 1 and No. 2 chains from the gears
  
  Fig 35: Removing Camshaft Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
1. Remove the 2 bolts and chain tensioner.
  
  Fig 36: Locating Chain Tensioner Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT TIMING GEAR KEY
1. Using a screwdriver, remove the 2 timing gear keys from the crankshaft.
REMOVE CAMSHAFT BEARING CAP LH (See REMOVAL )
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH (See REMOVAL )
REMOVE CAMSHAFT BEARING CAP RH (See REMOVAL )

Fig 37: Identifying Crankshaft Timing Gear Key
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH (See REMOVAL )
REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Remove the 32 valve rocker arms from the cylinder head
  HINT
  
  Arrange the removed parts in the correct order.
REMOVE VALVE LASH ADJUSTER ASSEMBLY
1. Remove the 32 valve lash adjusters from the cylinder head
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE VALVE STEM CAP
1. Remove the 32 valve stem caps from the cylinder head.
  HINT
  
  Arrange the removed parts in the correct order.
REMOVE CYLINDER HEAD SUB-ASSEMBLY LH (See REMOVAL )
REMOVE CYLINDER HEAD SUB-ASSEMBLY RH (See REMOVAL )
REMOVE CYLINDER BLOCK WATER JACKET SPACER
1. Remove the 2 water jacket spacers from the cylinder head.
  NOTE: Be sure to remove the water jacket spacers. If not, they may fall and become damaged when the cylinder block is inverted.
  
  Fig 38: Identifying Water Jacket Spacers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 HEAT EXCHANGER COVER
1. Remove the 12 bolts and 2 nuts
  
  Fig 39: Locating Heat Exchanger Cover Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the heat exchanger by prying between the heat exchanger and cylinder block with a screwdriver.
  HINT
  
  Tape the screwdriver tip before use.
  
  Fig 40: Removing Heat Exchanger Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VENTILATION PIPE GASKET
1. Using a screwdriver, pry out the ventilation pipe gasket.
  HINT
  
  Tape the screwdriver tip before use
  
  Fig 41: Removing Ventilation Pipe Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
1. Remove the 13 bolts and 2 nuts
  
  Fig 42: Locating No 2 Oil Pan Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Insert the blade of oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.
  NOTE: Be careful not to damage the contact surfaces of the oil pans.
  
  Fig 43: Removing No 2 Oil Pan
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 OIL PAN SUB-ASSEMBLY
1. Remove the 14 bolts and 2 nuts
  HINT.
  
  Be sure to clean the bolts and stud bolts, and check the threads for cracks or other damage LH Side.
  
  Fig 44: Locating No 1 Oil Pan Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the oil pan by prying between the oil pan and cylinder block 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 45: Removing No 2 Oil Pan
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 OIL PAN BAFFLE PLATE
1. Remove the 4 bolts and baffle plate.
  
  Fig 46: Locating No 1 Oil Pan Baffle Plate Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 OIL PAN BAFFLE PLATE
1. Remove the 4 bolts and baffle plate.
REMOVE ENGINE OIL LEVEL SENSOR (See REMOVAL )

Fig 47: Locating No 2 Oil Pan Baffle Plate Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL STRAINER SUB-ASSEMBLY
1. Remove the 2 bolts, oil strainer and O-ring.
  
  Fig 48: Locating Oil Strainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE REAR OIL SEAL RETAINER
1. Remove the 6 bolts.
  
  Fig 49: Locating Engine Rear Oil Seal Retainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, pry out the oil seal retainer.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 50: Removing Oil Seal Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL DRAIN PIPE SUB-ASSEMBLY
1. Remove the bolt and oil drain pipe.
2. Remove the O-ring
  
  Fig 51: Locating Oil Drain Pipe Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR CRANKSHAFT OIL SEAL
1. Place the oil seal retainer on wooden blocks.
2. Using a screwdriver and hammer, tap out the oil seal
REMOVE STRAIGHT PIN
NOTE: It is not necessary to remove the straight pins unless they are being replaced.
REMOVE STUD BOLT
NOTE: If the stud bolts are deformed or their threads are damaged, replace them.

Fig 52: Removing Rear Crankshaft Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002