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Engine Unit: Disassembly

  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
    1. Remove the oil filler cap.
    Fig 1: Locating Oil Filler Cap
    G06008852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE OIL FILLER CAP GASKET 
    1. Remove the gasket from the oil filler cap.
    Fig 2: Locating Oil Filler Cap Gasket
    G04974253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE ENGINE COVER JOINT 
    1. Remove the 2 engine cover joints.
    Fig 3: Locating Engine Cover Joints
    G06008854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE SPARK PLUG 
    1. Using a 14 mm spark plug wrench, remove the 4 spark plugs.
    Fig 4: Removing Spark Plug
    G06008855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE NO. 1 CRANK POSITION SENSOR 
    1. Remove the 2 bolts and 2 sensors.
    Fig 5: Locating No. 1 Crank Position Sensor Bolt
    G05399193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
    1. Remove the 2 bolts, O-rings, bracket and 2 oil control valves.
    Fig 6: Locating Camshaft Timing Oil Control Valve Assembly
    G05399194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 13 bolts, seal washer and cylinder head cover.
      NOTE: Be careful not to drop any of the gaskets into the engine when removing the cylinder head cover because the gaskets may stick to the cylinder head cover.
      Fig 7: Locating Cylinder Head Cover Sub-Assembly
      G05399195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the cylinder head cover gasket.
      Fig 8: Identifying Cylinder Head Cover Gasket
      G05399197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 gaskets from the camshaft bearing cap.
      Fig 9: Locating Camshaft Bearing Cap
      G05399196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. SET NO. 1 CYLINDER TO TDC/COMPRESSION  (See REMOVAL )
  9. REMOVE CRANKSHAFT PULLEY  (See REMOVAL )
  10. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Remove the 2 nuts, bracket, tensioner and gasket.
    NOTE: Do not turn the crankshaft without the chain tensioner installed.
    Fig 10: Locating No. 1 Chain Tensioner Assembly And Nut
    G05399201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE CRANKSHAFT POSITION SENSOR 
    1. Remove the bolt and sensor.
    Fig 11: Locating Crankshaft Position Sensor
    G05399202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
    Fig 12: Locating Engine Oil Pressure Switch Assembly
    G05399203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE NO. 1 TAPER SCREW PLUG 
    1. Remove the taper screw plug.
    Fig 13: Locating No. 1 Taper Screw Plug
    G05399204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE KNOCK CONTROL SENSOR 
    1. Remove the bolt and sensor.
    Fig 14: Locating Knock Control Sensor Bolt
    G05399205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using a 19 mm deep socket wrench, remove the sensor.
    2. Remove the gasket from the engine coolant temperature sensor.
      Fig 15: Identifying Engine Coolant Temperature Sensor
      G05399206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE OIL FILTER CAP ASSEMBLY  (See REPLACEMENT )
  17. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY  (See REMOVAL )
  18. REMOVE TIMING CHAIN COVER OIL SEAL 
    1. Using a screwdriver and hammer, remove the oil seal.
    NOTE: Be careful not to damage the timing chain cover.

    HINT:

    Tape the screwdriver tip before use.

    Fig 16: Removing Timing Chain Cover Oil Seal
    G05399741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE WATER INLET HOUSING 
    1. Remove the 3 bolts, gasket and water inlet housing.
    Fig 17: Locating Water Inlet Housing Bolt
    G05399219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 1 GENERATOR BRACKET 
    1. Remove the 4 bolts and No. 1 generator bracket.
      Fig 18: Locating No. 1 Generator Bracket Bolts
      G05399220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE CHAIN TENSIONER SLIPPER  (See REMOVAL )
  22. REMOVE NO. 1 CHAIN VIBRATION DAMPER  (See REMOVAL )
  23. REMOVE CHAIN SUB-ASSEMBLY  (See REMOVAL )
  24. REMOVE NO. 2 CHAIN VIBRATION DAMPER  (See REMOVAL )
  25. REMOVE CRANKSHAFT TIMING SPROCKET  (See REMOVAL )
  26. REMOVE NO. 2 CHAIN SUB-ASSEMBLY  (See REMOVAL )
  27. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE 
    1. Remove the No. 1 crankshaft position sensor plate.
    Fig 19: Locating No. 1 Crankshaft Position Sensor Plate
    G05399230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE CRANKSHAFT TIMING GEAR KEY 
    1. Using a screwdriver, remove the 2 crankshaft timing gear keys.

    HINT:

    Tape the screwdriver tip before use.

    Fig 20: Removing Crankshaft Timing Gear Keys
    G05399231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Check the lock of the camshaft timing gear.
    2. Release the lock pin.
      NOTE: Before removing the camshaft timing gear assembly, make sure that the lock pin has been released.
      Fig 21: Identifying Camshaft Timing Gear Sealing Area
      G05399232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. After cleaning and degreasing the WT oil hole on the intake side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.
        NOTE: Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.
      2. Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A)
      3. Apply approximately 150 kPa (1.5 kgf/cm2 , psi) of air pressure to the hole pricked in procedure A to release the lock pin.
        NOTE:
        • If air leaks out, reattach the adhesive tape.
        • Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.
        • Do not lock the camshaft timing gear assembly. If it is locked, release the lock pin again.
        Fig 22: Applying Air Pressure To Lock Pin
        G05399233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT:

        • The camshaft timing gear assembly may be turned in the advance direction without applying any force.
        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.
      4. Remove the adhesive tape from the No. 1 camshaft bearing cap.
    3. Remove the flange bolt while holding the hexagonal portion of the camshaft, then remove the camshaft timing gear assembly.
    NOTE:
    • Before removing the camshaft timing gear, make sure that the lock pin has been released.
    • Be sure not to remove the other 4 bolts.
    • Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.
    Fig 23: Identifying Camshaft Timing Gear Assembly
    G05399234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Remove the flange bolt while holding the hexagonal portion of the camshaft, then remove the camshaft timing exhaust gear assembly.
    NOTE:
    • Be sure not to remove the other 4 bolts.
    • Keep the camshaft timing exhaust gear assembly horizontal while removing it from the camshaft.
    Fig 24: Identifying Flange Bolt
    G06008875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE CAMSHAFT BEARING CAP 
    1. Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
      Fig 25: Locating Camshaft Bearing Cap Bolts Loosen Sequence
      G05399236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Uniformly loosen and remove the 15 bearing cap bolts in the sequence shown in the illustration.
      NOTE: Uniformly loosen the bolts while keeping the camshaft level.
    3. Remove the 5 bearing caps.

      HINT:

      Arrange the removed parts in the correct order.

      Fig 26: Locating Camshaft Bearing Cap Bolts Loosen Sequence
      G05399237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE CAMSHAFT 
    1. Remove the camshaft.
    Fig 27: Identifying Camshaft
    G05399238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE NO. 2 CAMSHAFT 
    1. Remove the No. 2 camshaft.
    Fig 28: Identifying No. 2 Camshaft
    G05399239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Remove the 16 valve rocker arms.

    HINT:

    Arrange the removed parts in the correct order.

    Fig 29: Locating Valve Rocker Arms
    G05399240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE VALVE LASH ADJUSTER ASSEMBLY 
    1. Remove the 16 valve lash adjusters from the cylinder head.

    HINT:

    Arrange the removed parts in the correct order.

    Fig 30: Identifying Valve Lash Adjuster Assembly
    G05399241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE OIL CONTROL VALVE FILTER 
    1. Remove the oil control valve filter.
    Fig 31: Removing Oil Control Valve Filter
    G05398404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE NO. 1 CAMSHAFT BEARING 
    1. Remove the 2 No. 1 camshaft bearings.
    Fig 32: Identifying No. 1 Camshaft Bearings
    G05399243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE NO. 2 CAMSHAFT BEARING 
    1. Remove the 2 No. 2 camshaft bearings.
    Fig 33: Identifying No. 2 Camshaft Bearing
    G05399244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY 
    1. Remove the 2 bolts.
      Fig 34: Locating Camshaft Housing Sub-Assembly Bolts
      G05398910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.
      Fig 35: Prying Between Cylinder Head And Camshaft Housing
      G05398911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

    HINT:

    Tape the screwdriver tip before use.

  40. REMOVE CYLINDER HEAD SUB-ASSEMBLY  (See REMOVAL )
  41. REMOVE CYLINDER HEAD GASKET  (See REMOVAL )
  42. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. Remove the water drain cock plug from the water drain cock sub-assembly.
    2. Remove the cylinder block water drain cock sub-assembly from the cylinder block.
    Fig 36: Removing Cylinder Block Water Drain Cock Sub-Assembly
    G05399248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE VENTILATION VALVE SUB-ASSEMBLY 
    1. Remove the ventilation valve.
    Fig 37: Locating Ventilation Valve
    G05399249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE OIL PAN DRAIN PLUG 
    1. Remove the oil pan drain plug and gasket.
      Fig 38: Locating Oil Pan Drain Plug
      G05399250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY  (See REMOVAL )
  46. REMOVE OIL PUMP ASSEMBLY  (See DISASSEMBLY )
  47. REMOVE REAR ENGINE OIL SEAL 
    1. Using a knife, cut off the oil seal lip.
    2. Using a screwdriver with its tip taped, pry out the oil seal.
    NOTE: After removing the oil seal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper.
    Fig 39: Removing Rear Engine Oil Seal
    G05399069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE STIFFENING CRANKCASE ASSEMBLY 
    1. Uniformly loosen and remove the 11 bolts.
      Fig 40: Locating Stiffening Crankcase Assembly Bolts Loosen Sequence
      G05399254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the crankcase by prying between the crankcase and cylinder block.
    NOTE: Be careful not to damage the contact surfaces of the crankcase and cylinder block.
    Fig 41: Prying Between Crankcase And Cylinder Block
    G05399255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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