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Engine Unit: Disassembly: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
    1. Remove the oil filler cap from the cylinder head cover.
      Fig 1: Locating Oil Filler Cap
      GTY164542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE OIL FILLER CAP GASKET 
    1. Remove the oil filler cap gasket from the oil filler cap.
      Fig 2: Locating Oil Filler Cap Gasket
      GTY161447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE VENTILATION VALVE SUB-ASSEMBLY 
    1. Using a 22 mm deep socket wrench, remove the ventilation valve from the cylinder head cover.
      Fig 3: Locating Ventilation Valve
      GTY167096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE SPARK PLUG  . Refer to REMOVAL - Step 3
  5. REMOVE OIL FILTER SUB-ASSEMBLY  . Refer to REPLACEMENT - Step 2
  6. REMOVE OIL FILTER UNION 
    1. Using a 12 mm socket hexagon wrench, remove the oil filter union.
      Fig 4: Locating Oil Filter Union
      GTY166123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 8 bolts and 2 nuts, and remove the cylinder head cover.
      Fig 5: Locating Cylinder Head Cover Bolts And Nuts
      GTY162432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE CYLINDER HEAD COVER GASKET 
    1. Remove the cylinder head cover gasket from the cylinder head cover.
      Fig 6: Identifying Cylinder Head Cover Gasket
      GTY165264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY  See step  46
  10. REMOVE CRANKSHAFT POSITION SENSOR 
    1. Remove the wire harness clamp.
      Fig 7: Locating Clamp Of Crankshaft Position Sensor From Water Pump
      GTY162722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Separate the wire harness from the wire harness clamp bracket.
    3. Remove the 2 bolts and sensor.
      Fig 8: Locating Sensor And Bolts
      GTY191157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE CAMSHAFT POSITION SENSOR 
    1. Remove the bolt and camshaft position sensor.
      Fig 9: Locating Camshaft Position Sensor Bolt
      GTY165641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. SET NO. 1 CYLINDER TO TDC/COMPRESSION  See step  43
  13. REMOVE CRANKSHAFT PULLEY  See step  4
  14. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
    1. Remove the bolt and camshaft timing oil control valve from the cylinder head.
      Fig 10: Locating Camshaft Timing Oil Control Valve Bolt
      GTY161450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      The camshaft timing oil control valve may be damaged when loosening the cylinder head bolts if the oil control valve is not removed.

    2. Remove the O-ring from the camshaft timing oil control valve.
  15. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY  See step  45
  16. REMOVE WATER PUMP PULLEY  . Refer to REMOVAL - Step 9
  17. REMOVE WATER PUMP ASSEMBLY  . Refer to REMOVAL - Step 10
  18. REMOVE OIL PAN DRAIN PLUG 
    1. Remove the oil pan drain plug from the oil pan.
      Fig 11: Locating Oil Pan Drain Plug
      GTY161451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Remove the 12 bolts and 2 nuts.
      Fig 12: Locating Oil Pan Sub-Assembly Bolts And Nuts
      GTY161452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the blade of an oil pan seal cutter between the crankcase, chain cover and oil pan, then cut through the applied sealer and remove the oil pan.
      Fig 13: Inserting Blade Of Oil Pan Seal Cutter Between Oil Pans
      GTY104871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the contact surfaces of the crankcase, chain cover and oil pan.

  20. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY  . Refer to REMOVAL - Step 48
  21. REMOVE FRONT CRANKSHAFT OIL SEAL  . Refer to REMOVAL - Step 49
  22. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE  See step  49
  23. REMOVE TIMING CHAIN GUIDE  See step  50
  24. REMOVE CHAIN TENSIONER SLIPPER  See step  51
  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER  See step  52
  26. REMOVE CHAIN SUB-ASSEMBLY 
  27. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET  See step  54
  28. REMOVE NO. 2 CHAIN SUB-ASSEMBLY  See step  55
  29. REMOVE KEYS 
    1. Remove the 2 pulley set keys from the crankshaft.
      Fig 14: Identifying Pulley Set Keys
      GTY182093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE NO. 2 CAMSHAFT 
    1. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
      Fig 15: Identifying Bearing Cap Bolts In Loosening Sequence
      GTY191717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Uniformly loosen the bolts while keeping the camshaft level.

      HINT: 

      Arrange the removed parts in the correct order.

    2. Remove the 5 bearing caps.
    3. Remove the No. 2 camshaft.
  31. REMOVE CAMSHAFT 
    1. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
      Fig 16: Identifying Bearing Cap Bolts In Loosening Sequence
      GTY190444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Uniformly loosen the bolts while keeping the camshaft level.

      HINT: 

      Arrange the removed parts in the correct order.

    2. Remove the 5 bearing caps.
    3. Remove the camshaft.
  32. REMOVE NO. 1 CAMSHAFT BEARING 
    1. Remove the camshaft bearing from the No. 1 camshaft bearing cap.
      Fig 17: Identifying Camshaft Bearing
      GTY161455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE NO. 2 CAMSHAFT BEARING 
    1. Remove the No. 2 camshaft bearing from the cylinder head.
      Fig 18: Identifying Camshaft Bearing Location
      GTY162688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET 
    1. Clamp the camshaft in a vise.
      Fig 19: Installing Camshaft Timing Sprocket
      GTY191079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not overtighten the vise.
      • Do not damage the camshaft.
    2. Remove the bolt and camshaft timing gear or sprocket.
  35. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY  See step  11
  36. REMOVE CYLINDER HEAD SUB-ASSEMBLY  See step  64
  37. REMOVE CYLINDER HEAD GASKET 
    Fig 20: Identifying Cylinder Head Gasket
    GTY164940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    1. Using needle nose pliers, remove the cylinder block water jacket spacer from the water jacket.
      Fig 21: Identifying Cylinder Block Water Jacket Spacer
      GTY192397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Before turning the cylinder block upside down, make sure that the water jacket spacer is removed, as it will fall out.

  39. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    1. Remove the water drain cock from the stiffening crankcase.
      Fig 22: Identifying Cylinder Block Water Drain Cock Sub-Assembly
      GTY192398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the water drain cock plug from the water drain cock.
  40. REMOVE OIL CONTROL VALVE FILTER 
    1. Using an 8 mm socket hexagon wrench, remove the plug, gasket and oil control valve filter.
      Fig 23: Identifying Oil Control Valve Filter
      GTY161460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE NO. 1 TAPER HEAD SCREW PLUG 
    1. Remove the No. 1 taper head screw plug.
      Fig 24: Identifying No. 1 Taper Head Screw Plug
      GTY161387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE OIL PUMP ASSEMBLY  . Refer to REMOVAL - Step 60
  43. INSPECT BALANCESHAFT THRUST CLEARANCE  See step  1
  44. INSPECT BALANCESHAFT OIL CLEARANCE  See step  2
  45. REMOVE NO. 1 AND NO. 2 BALANCESHAFTS 
    1. Remove the No. 1 and No. 2 balanceshafts.
      Fig 25: Identifying No. 1 And No. 2 Balanceshafts
      GTY192508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE NO. 1 BALANCESHAFT BEARING 
    1. Remove the 8 No. 1 balanceshaft bearings shown in the illustration.
      Fig 26: Removing/Installing No. 1 Balanceshaft Bearings
      GTY232599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE REAR CRANKSHAFT OIL SEAL  See step  7
  48. REMOVE STIFFENING CRANKCASE ASSEMBLY 
    1. Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.
      Fig 27: Identifying Stiffening Crankcase Assembly Bolts Sequence
      GTY165739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver with its tip wrapped with protective tape, remove the crankcase by prying between the crankcase and cylinder block.
      Fig 28: Removing Crankcase By Prying Portions Between Crankcase And Cylinder Block
      GTY161388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the contact surfaces between the crankcase and cylinder block.

    3. Remove the O-ring from the cylinder block.
      Fig 29: Identifying O-Ring From Cylinder Block
      GTY176160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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