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Engine Unit: Disassembly

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
    1. Remove the oil filler cap sub-assembly.
    2. Remove the oil filler cap gasket from the oil filler cap.
  2. REMOVE OIL FILLER CAP HOUSING 
    1. Remove the 2 bolts, oil filler cap housing and oil filler cap housing gasket.
  3. REMOVE SPARK PLUG  (See REMOVAL )
  4. REMOVE OIL PAN DRAIN PLUG 
    1. Remove the oil pan drain plug and gasket from the No. 2 oil pan.
    Fig 1: Locating Oil Filler Cap Housing Bolts
    G05749572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE VVT SENSOR 
    1. for Bank 1

      Remove the 2 bolts and 2 VVT sensors.

      Fig 2: Locating VVT Sensors Bolts (For Bank 1)
      G05749573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Bank 2

      Remove the 2 bolts and 2 VVT sensors.

      Fig 3: Locating VVT Sensors Bolts (For Bank 2)
      G05749574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE CAMSHAFT POSITION SENSOR 
    1. Remove the bolt and camshaft position sensor.
    Fig 4: Locating Camshaft Position Sensor Bolt
    G05749575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE CRANKSHAFT POSITION SENSOR 
    1. Remove the bolt and crankshaft position sensor.
    Fig 5: Locating Crankshaft Position Sensor Bolt
    G05749576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY LH 
    1. Remove the bolt and camshaft timing oil control valve assembly LH
    2. Remove the O-ring from the camshaft timing oil control valve assembly LH.
    Fig 6: Locating Camshaft Timing Oil Control Valve Assembly LH Bolt
    G05749577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH 
    1. Remove the bolt and camshaft timing oil control valve assembly RH.
    2. Remove the O-ring from the camshaft timing oil control valve assembly RH
    Fig 7: Locating Camshaft Timing Oil Control Valve Assembly RH Bolt
    G05749578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. Remove the 2 cylinder block water drain cock plugs from the cylinder block water drain cock sub-assembly
    2. Remove the 2 cylinder block water dram cock sub-assembly from the cylinder block
    Fig 8: Locating Cylinder Block Water Drain Cock Plugs
    G05749579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY LH (for Bank 1) 
    1. Remove the 3 bolts and the camshaft timing control motor assembly LH
    2. Remove the O-ring from the camshaft timing control motor assembly LH
    Fig 9: Locating Camshaft Timing Control Motor Assembly LH Bolts
    G05749580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY RH (for Bank 2) 
    1. Remove the 3 bolts and the camshaft timing control motor assembly RH.
    2. Remove the O-ring from the camshaft timing control motor assembly RH.
    Fig 10: Locating Camshaft Timing Control Motor Assembly RH Bolts
    G05749581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FRONT WATER BY-PASS JOINT 
    1. Remove the 4 nuts, front water by-pass joint and 2 gaskets.
    Fig 11: Locating Front Water By-Pass Joint Nuts
    G05749582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE OIL FILTER ELEMENT 
    1. Using a SST, temporarily loosen the oil filter cap by approximately 4 turns.

      SST 09228-06501 

      HINT:

      Make sure that the oil filter cap ribs are vertical, this will allow the engine oil to drain from the gap between the oil filter cap and the housing

    2. Remove the oil filter cap.
      Fig 12: Loosening Oil Filter Cap
      G05749583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the oil filter element and O-ring from the oil filter cap.
      NOTE: Be sure to remove the O-ring (for the cap) by hand, without using any tools, to prevent damage to the groove for the O-ring on the cap.
      Fig 13: Identifying Oil Filter Element And O-Ring
      G05749584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE OIL COOLER ASSEMBLY 
    1. Remove the bolt.
    2. Remove the union bolt, gasket and oil cooler assembly.
    Fig 14: Locating Oil Cooler Assembly Union Bolt
    G05749585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE OIL FILTER BRACKET 
    1. Remove the 2 bolts and oil filter bracket stay
      Fig 15: Locating Oil Filter Bracket Stay Bolts
      G05750436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts, 2 nuts and oil filter bracket.
    3. Remove the 2 gaskets from the timing chain cover sub-assembly.
  17. REMOVE CRANKSHAFT PULLEY  (See REMOVAL )
    Fig 16: Locating Oil Filter Bracket Bolts And Nuts
    G05749587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE NO. 1 V-BANK COVER BRACKET (for Bank 1) 
    1. Remove the No 1 V-bank cover bracket from the cylinder head cover sub-assembly LH.
    Fig 17: Locating V-Bank Cover Bracket (For Bank 1)
    G05749588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 1 V-BANK COVER BRACKET (for Bank 2) 
    1. Remove the No. 1 V-bank cover bracket from the cylinder head cover sub-assembly.
    Fig 18: Locating V-Bank Cover Bracket (For Bank 2)
    G05749589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (for Bank 1) 
    1. Remove the fuel pump spacer gasket
    2. Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly LH and cylinder head cover gasket LH

      HINT

      Make sure that the removed parts are returned to the original places they were removed from

      Fig 19: Locating Cylinder Head Cover Bolts
      G05749590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 oil hole gaskets and 2 O-rings from the camshaft bearing caps
    Fig 20: Locating Oil Hole Gaskets And O-Rings
    G05749591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2) 
    1. Remove the fuel pump spacer gasket
    2. Remove the 16 bolts, 3 seal washers, cylinder head cover sub-assembly and cylinder head cover gasket.

      HINT.

      Make sure that the removed parts are returned to the original places they were removed from

      Fig 21: Locating Cylinder Head Cover Bolts
      G05749592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 oil hole gaskets and 2 O-rings from the camshaft bearing caps.
    Fig 22: Locating Oil Hole Gaskets And O-Rings
    G05749593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE SPARK PLUG TUBE GASKET 
    1. Using a screwdriver, pry out the 8 spark plug tube gaskets from the each cylinder head sub-assembly.

      HINT

      Tape the screwdriver tip before use.

      Fig 23: Removing Spark Plug Tube Gasket
      G05749594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE OIL CONTROL VALVE FILTER 
    1. for Bank 1.
      1. Remove the 2 bolts, cylinder head cover spacer LH, gasket and oil control valve filter.
      Fig 24: Locating Oil Control Valve Filter Bolts (For Bank 1)
      G05749595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Bank 2:
      1. Remove the 2 bolts, cylinder head cover spacer, gasket and oil control valve filter
      Fig 25: Locating Oil Control Valve Filter Bolts (For Bank 2)
      G05749596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the standard bolt, 6 mm hexagon bolt and V-ribbed belt tensioner assembly
  25. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY  (See REMOVAL )
  26. REMOVE INLET WATER PIPE  (See REMOVAL )
    Fig 26: Locating V-Ribbed Belt Tensioner Hexagon Bolt
    G05750463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE WATER PUMP ASSEMBLY 
    1. Remove the 5 bolts, water pump assembly and water pump gasket from the timing chain cover sub-assembly.
  28. REMOVE NO. 1 OIL PIPE  (See REMOVAL )
  29. REMOVE NO. 2 OIL PIPE  (See REMOVAL )
  30. REMOVE NO. 3 OIL PIPE  (See REMOVAL )
  31. REMOVE SCAVENGING PUMP ASSEMBLY  (See REMOVAL )
    Fig 27: Locating Water Pump Assembly Bolts
    G05749598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE TIMING CHAIN CASE OIL SEAL 
    1. Using screwdriver, remove the timing chain case oil seal

      HINT.

      Tape the screwdriver tip before use.

      Fig 28: Removing Timing Chain Case Oil Seal
      G05749599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Temporarily tighten the crankshaft pulley set 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.

      Fig 29: Aligning Timing Marks On Crankshaft Timing Gear And Camshaft Timing Gears
      G05749600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1) 
    1. Move the stopper plate upward to release the lock, and fully push the plunger into the tensioner
    2. Move the stopper plate downward to set the lock, and insert a 2 mm hexagon wrench into the stopper plate hole
      Fig 30: Moving Stopper Plate Upward And Downward
      G04943343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and chain tensioner.
    4. Remove the chain tensioner gasket
    Fig 31: Locating Chain Tensioner Bolts
    G04943344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE CHAIN TENSIONER SLIPPER (for Bank 1) 
    1. Remove the chain tensioner slipper.
    Fig 32: Identifying Chain Tensioner Slipper
    G05749603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 1) 
    1. Remove the 2 bolts and chain vibration damper.
    Fig 33: Locating Chain Vibration Damper Bolts
    G05749604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE CHAIN SUB-ASSEMBLY (for Bank 1) 
    1. While pushing down the No. 3 chain tensioner, insert a 1.0 mm (0 0394 in.) pin into the hole to fix it in place.
      Fig 34: Inserting Pin Into Hole
      G05749605Courtesy 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 35: Loosening Camshaft Bolt
      G05749606Courtesy 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 chain sub-assembly and No. 2 chain sub-assembly still connected to the gears, remove the camshaft timing gear assembly, camshaft timing exhaust gear and crankshaft timing sprocket LH.
    5. Remove the No. 1 chain sub-assembly and No. 2 chain sub-assembly from the gears.
    Fig 36: Loosening Camshaft Bolt
    G05749607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY (for Bank 1) 
    1. Remove the 2 bolts and No 3 chain tensioner assembly.
    Fig 37: Locating Chain Tensioner Bolts
    G05749608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2) 
    1. Move the stopper plate upward to release the lock, and fully push the plunger into the tensioner
    2. Move the stopper plate downward to set the lock, and insert a 2 mm hexagon wrench into the stopper plate hole
      Fig 38: Moving Stopper Plate Upward And Downward
      G05749609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and No 1 chain tensioner assembly
    Fig 39: Locating Chain Tensioner Bolts
    G04943351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE CHAIN TENSIONER SLIPPER (for Bank 2) 
    1. Remove the chain tensioner slipper.
    Fig 40: Identifying Chain Tensioner Slipper
    G05749611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 2) 
    1. Remove the 2 bolts and No. 1 chain vibration damper.
    Fig 41: Locating Chain Vibration Damper Bolts
    G04943352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE CHAIN SUB-ASSEMBLY (for Bank 2) 
    1. While raising up the No. 2 chain tensioner, insert a 1.0 mm (0.0394 in.) pin into the hole to fix it in place
      Fig 42: Inserting Pin Into Hole
      G05749613Courtesy 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 43: Loosening Camshaft Bolt
      G05749614Courtesy 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 chain sub-assembly and No 2 chain sub-assembly still connected to the gears, remove the camshaft timing gear assembly, camshaft timing exhaust gear and crankshaft timing gear.
    5. Remove the No. 1 chain sub-assembly and No 2 chain sub-assembly from the gears
    Fig 44: Loosening Camshaft Bolt
    G05749615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY (for Bank 2) 
    1. Remove the 2 bolts and chain tensioner
    Fig 45: Locating Chain Tensioner Bolts
    G05749616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE CRANKSHAFT TIMING GEAR KEY 
    1. Using a screwdriver, remove the 2 timing gear keys from the crankshaft.
    Fig 46: Identifying Crankshaft Timing Gear Keys
    G04943663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE OIL REFLECTOR PLATE LH (for Bank 1) 
    1. Remove the 2 bolts and oil reflector plate LH from the cylinder head assembly LH
  46. REMOVE CAMSHAFT BEARING CAP (for Bank 1)  (See REMOVAL )
  47. REMOVE NO. 3 CAMSHAFT  (See REMOVAL )
  48. REMOVE NO. 4 CAMSHAFT  (See REMOVAL )
    Fig 47: Locating Oil Reflector Plate LH Bolts (For Bank 1)
    G05749618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE OIL REFLECTOR PLATE RH (for Bank 2) 
    1. Remove the 2 bolts and oil reflector plate RH from the cylinder head assembly
  50. REMOVE CAMSHAFT BEARING CAP (for Bank 2)  (See REMOVAL )
  51. REMOVE CAMSHAFT  (See REMOVAL )
  52. REMOVE NO. 2 CAMSHAFT  (See REMOVAL )
    Fig 48: Locating Oil Reflector Plate RH Bolts (For Bank 1)
    G05749619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Remove the 32 No. 1 valve rocker arms from the cylinder heads.

      HINT.

      Arrange the removed parts in the correct order.

  54. REMOVE VALVE ROCKER ARM PIVOT 
    1. Remove the 32 valve rocker arm pivots from the cylinder head sub-assembly.
  55. REMOVE CYLINDER HEAD SUB-ASSEMBLY (for Bank 1)  (See REMOVAL )
  56. REMOVE NO. 2 CYLINDER HEAD GASKET (for Bank 1)  (See REMOVAL )
  57. REMOVE CYLINDER HEAD SUB-ASSEMBLY (for Bank 2)  (See REMOVAL )
    Fig 49: Identifying Valve Rocker Arms
    G05749620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE CYLINDER HEAD GASKET (for Bank 2)  (See REMOVAL )
  59. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    1. Remove the 2 cylinder block water jacket spacers from the cylinder block.
    NOTE: Be sure to remove the cylinder block water jacket spacers. Otherwise, they may fall out and be damaged when the cylinder block is inverted.
    Fig 50: Identifying Cylinder Block Water Jacket Spacers
    G05749621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. REMOVE HEAT EXCHANGER ASSEMBLY 
    1. Remove the bolt
      Fig 51: Locating Heat Exchanger Bolt
      G05749622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 11 bolts and 2 nuts.
      Fig 52: Locating Heat Exchanger Assembly Bolts And Nuts
      G05749623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the heat exchanger assembly by prying between the heat exchanger assembly and cylinder block with a screwdriver.

      HINT

      Tape the screwdriver tip before use.

      Fig 53: Removing Heat Exchanger Assembly
      G05749624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. REMOVE VENTILATION PIPE GASKET 
    1. Using a screwdriver, pry out the ventilation pipe gasket

      HINT

      Tape the screwdriver tip before use

    Fig 54: Removing Ventilation Pipe Gasket
    G05749625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Remove the 15 bolts and 2 nuts
      Fig 55: Locating Oil Pan Bolts And Nuts
      G04943628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the blade of an oil pan cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly
      NOTE: Be careful not to damage the contact surfaces of the oil pans.
      Fig 56: Removing Oil Pan Sub-Assembly
      G05683050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. REMOVE 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.

      Fig 57: Locating Oil Pan Bolts And Nuts
      G04943630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the oil pan sub-assembly 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 sub-assembly.

      HINT.

      Tape the screwdriver tip before use.

      Fig 58: Locating Contact Surfaces Of Cylinder Block And Oil Pan
      G04943631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE NO. 1 OIL PAN BAFFLE PLATE 
    1. Remove the 8 bolts and No. 1 oil pan baffle plate
    Fig 59: Locating Oil Pan Baffle Plate Bolts
    G05749630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the 2 bolts, oil strainer sub-assembly and O-ring
    Fig 60: Locating Oil Strainer Bolts
    G04943633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. REMOVE ENGINE REAR OIL SEAL RETAINER 
    1. Remove the 6 bolts
      Fig 61: Locating Engine Rear Oil Seal Retainer Bolts
      G04943634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver with its tip taped, pry out the engine rear oil seal retainer.
    Fig 62: Removing Engine Rear Oil Seal Retainer
    G04943635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY 
    1. Remove the bolt and oil drain pipe sub-assembly.
    2. Remove the O-ring.
    Fig 63: Locating Oil Drain Pipe Bolt
    G05151290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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