Engine Unit Disassembly

Disconnect the sensor connector.

Remove the bolt and sensor.

Disconnect the sensor wire harness clamp.

Remove the bolt and sensor.

Install the 2 bolts to the bolt holes of the crankshaft rear side.

Using a bar, turn the crankshaft until the crankshaft pulley service hole is a little to the left of bottom dead center.

Install a 14 mm x 1.5 pitch service bolt with a length of 70 mm or more to the crankshaft pulley service hole, and hold the crankshaft using the timing chain cover protrusion.

Remove the 3 bolts and crankshaft pulley.

NOTICE:

If the crankshaft pulley cannot be removed, temporarily install a bolt to the crankshaft so that the pulley does not fall, and lightly tap the outer edge of the mass damper with a plastic-faced hammer to remove the pulley. Do not tap the pulley V-ribbed belt ribs, as the crankshaft may be damaged.

Remove the 2 bolts and timing gear cover spacer.

Remove the oil filter drain plug.

Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

Remove the O-ring from the oil filter drain plug and install it to the drain pipe.

Install the oil filter drain pipe to the oil filter cap and drain the engine oil.

Remove the oil filter drain pipe.

Apply a light coat of engine oil to a new O-ring, and install it to the oil filter drain plug.

Install the oil filter drain plug to the oil filter cap.

Torque:

13 N*m{127 kgf*cm, 9 ft.*lbf}

Using SST, remove the oil filter cap.

SST

09228-06501

HINT:

Use a container to catch the draining oil. After the oil filter cap is loosened approximately 4 turns and the cap ribs are vertical, engine oil drains from the gap between the oil filter cap and oil pan.

Remove the oil filter element and O-ring from the oil filter cap.

NOTICE:

Be sure to remove the cap O-ring by hand, without using any tools, to prevent damage to the cap O-ring groove.

Disconnect the oil pressure sender gauge connector.

Remove the oil pressure sender gauge.

Remove the 2 bolts, 2 nuts and oil cooler.

Remove the 2 O-rings and oil cooler gasket.

Remove the oil cooler relief valve and gasket.

Remove the 3 bolts, 2 nuts and oil filter bracket.

Remove the 2 O-rings.

Remove the 4 bolts and engine oil level sensor.

Remove the gasket.

Remove the oil pan drain plug and gasket.

Remove the 10 bolts and 2 nuts.

Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

NOTICE:

Be careful not to damage the contact surfaces of the No. 1 and No. 2 oil pans.

Remove the 2 bolts and oil strainer.

Remove the O-ring from the oil strainer.

Remove the 20 bolts, 2 nuts and oil reflector plate.

NOTICE:

If the oil reflector plate is deformed, replace it.

HINT:

Be sure to clean the bolts and stud bolts, and check the threads for cracks or other damage.

Remove the No. 1 oil pan by prying between the No. 1 oil pan and cylinder block with a screwdriver.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder block and oil pan.

HINT:

Tape the screwdriver tip before use.

Remove the 3 O-rings.

Remove the cylinder block oil hole gasket.

Remove the 5 bolts and No. 1 oil pan baffle plate.

Remove the 3 bolts and inlet oil pump pipe.

Remove the O-ring from the inlet oil pump pipe.

Remove the 4 bolts and oil regulator.

Remove the 10 bolts.

Remove the oil seal retainer by prying between the oil seal retainer and cylinder block with a screwdriver.

HINT:

Tape the screwdriver tip before use.

Place the oil seal retainer on wooden blocks.

Using a screwdriver and hammer, tap out the oil seal.

HINT:

Tape the screwdriver tip before use.

Remove the 4 bolts and oil pump.

Remove the 4 bolts and scavenging pump.

Remove the 18 bolts, cylinder head cover and gasket.

Using a small screwdriver and hammer, remove the 4 nozzle holder gaskets.

HINT:

Tape the screwdriver tip before use.

Using a small screwdriver, remove the 4 holder seals by prying the portion between each holder seal and the cutout part of the cylinder head cover.

HINT:

Tape the screwdriver tip before use.

Remove the 4 bolts, 4 washers, 4 nozzle holder clamps, 4 nozzle holder seals and 4 fuel injectors.

HINT:

Arrange the fuel injectors, holder clamps, washers and bolts in the correct order.

Remove the O-ring from each fuel injector.

Remove the fuel injector seal from each fuel injector.

Remove the 4 injection nozzle seats from the cylinder head sub-assembly.

Remove the 19 bolts, 4 nozzle holder clamp seats and cylinder head cover RH.

Text in Illustration

	Bolt
	Nozzle Holder Clamp Seat

Remove the cylinder head cover gasket RH and No. 3 cylinder head cover gasket from the cylinder head cover RH.

Remove the bolt and No. 2 fuel pump bracket.

Remove the 4 bolts, 4 washers, 4 nozzle holder clamps, 4 nozzle holder seals and 4 fuel injectors.

HINT:

Arrange the fuel injectors, holder clamps, washers and bolts in the correct order.

Remove the O-ring from each fuel injector.

Remove the fuel injector seal from each fuel injector.

Remove the 4 injection nozzle seats from the cylinder head sub-assembly.

Remove the 3 bolts, oil separator and gasket.

Remove the 18 bolts, 4 nozzle holder clamp seats and cylinder head cover LH.

Text in Illustration

	Bolt
	Nozzle Holder Clamp Seat

Remove the cylinder head cover gasket LH and No. 4 cylinder head cover gasket from the cylinder head cover LH.

Remove the 17 bolts, cylinder head cover and gasket.

Using a small screwdriver and hammer, remove the 4 nozzle holder gaskets.

HINT:

Tape the screwdriver tip before use.

Using a small screwdriver, remove the 4 holder seals by prying the portion between each holder seal and the cutout part of the cylinder head cover.

HINT:

Tape the screwdriver tip before use.

Remove the union bolt, 4 hollow screws, 5 gaskets and nozzle leakage pipe.

Text in Illustration

Union Bolt

NOTICE:

1. When removing the nozzle leakage pipe, place a cushion under the pipe.
   
2. Be careful not to deform or scratch the union seal surface.
   
3. After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
   

Remove the 4 bolts, 4 washers, 4 nozzle holder clamps and 4 injectors.

HINT:

Arrange the injectors, holder clamps, washers and bolts in the correct order.

Remove the O-ring from each injector.

Remove the 4 injection nozzle seats from the cylinder head.

Remove the union bolt, 4 hollow screws, 5 gaskets and No. 2 nozzle leakage pipe.

Text in Illustration

Union Bolt

NOTICE:

1. When removing the nozzle leakage pipe, place a cushion under the pipe.
   
2. Be careful not to deform or scratch the union seal surface.
   
3. After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
   

Remove the 4 bolts, 4 washers, 4 nozzle holder clamps and 4 injectors.

HINT:

Arrange the injectors, holder clamps, washers and bolts in the correct order.

Remove the O-ring from each injector.

Remove the 4 injection nozzle seats from the cylinder head.

Remove the 9 bolts, 2 nuts, water pump and gasket.

Remove the 4 bolts, cover plate and gasket.

Remove the 4 nuts and 16 bolts.

Using a screwdriver, remove the timing chain cover by prying between the timing chain cover and timing gear case.

HINT:

Tape the screwdriver tip before use.

Remove the O-ring from the timing gear case.

Place the timing chain cover on wooden blocks.

Using a screwdriver and wooden block, pry out the oil seal.

NOTICE:

Do not damage the surface of the oil seal press fit hole.

HINT:

Tape the screwdriver tip before use.

Temporarily install the 2 crankshaft pulley set bolts to the crankshaft.

Turn the crankshaft clockwise to set the No. 1 cylinder to TDC.

With the crankshaft key 45° counterclockwise from the top position, check that the timing marks of the RH and LH camshaft timing gears are aligned. If not as specified, turn the crankshaft 1 revolution (360°) and align the timing marks as shown below.

Remove the 2 crankshaft pulley set bolts.

Using a T30 "TORX" wrench, remove the 2 screws and crankshaft position sensor plate.

Using SST, hold the pump drive shaft gear.

SST

09960-10010(09962-01000,09963-01000)

Remove the 4 bolts and pump drive shaft gear.

Push the tensioner slipper away from the tensioner, and move the stopper plate clockwise to release the lock as shown in A.

Push down the tensioner slipper and move the stopper plate counterclockwise to set the lock as shown in B.

Push the tensioner slipper away from the tensioner, and insert a hexagon wrench into the stopper plate hole as shown in C.

Remove the 2 bolts and No. 1 chain tensioner.

Remove the 2 bolts and No. 1 chain vibration damper.

Push the tensioner slipper away from the tensioner, and move the stopper plate clockwise to release the lock as shown in A.

Push up the tensioner slipper and move the stopper plate counterclockwise to set the lock as shown in B.

Push the tensioner slipper away from the tensioner, and insert a hexagon wrench into the stopper plate hole as shown in C.

Remove the 2 bolts and No. 2 chain tensioner.

Remove the 2 bolts and No. 2 chain vibration damper.

Using SST, hold the No. 2 camshaft timing sprocket.

SST

09960-10010(09962-01000,09963-01000)

Remove the 4 bolts, No. 2 camshaft timing sprocket and No. 2 timing chain.

Using SST, hold the idle gear.

SST

09960-10010(09962-01000,09963-00700)

Remove the nut.

w/ Intercooler:
Using an 8 mm x 1.25 pitch service bolt with a length of 15 mm or more, fix the idle gear in place.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

Remove the 2 bolts, idle gear thrust plate and idle gear.

Hold the idle gear in a vise between aluminum plates.

NOTICE:

Be careful not to damage the gears.

Using SST, hole the idle gear, and remove the bolt and sub idle gear.

SST

09960-10010(09962-01000,09963-00700)

Remove the idle gear spring from the idle gear.

Using SST, remove the fuel supply pump drive gear.

SST

09950-50013(09951-05010,09952-05010,09953-05020,09954-05031)

Turn the bearing, and check that the bearing moves smoothly and quietly.
If it moves roughly or noisily, replace the radial ball bearing.

Using SST, remove the radial ball bearing.

SST

09950-00020
09950-00030
09950-60010(09951-00580)
09950-40011(09957-04010)

Hold the fuel supply pump shaft sprocket in a vise between aluminum plates.

NOTICE:

Be careful not to damage the gears.

Remove the 4 bolts and separate the fuel supply pump drive gear and fuel supply pump shaft sprocket.

Remove the straight pin.

Using a 6 mm hexagon wrench, remove the hexagon bolt. Then remove the 2 nuts and fuel supply pump.

Remove the O-ring.

Remove the 22 bolts, 2 nuts and timing gear case shown in the illustration.

Remove the 2 O-rings and timing gear case gasket.

Remove the 2 bolts and No. 1 vacuum transmitting pipe.

Remove the 3 bolts and No. 2 vacuum transmitting pipe.

Using a 6 mm x 1.0 pitch service bolt with a length of 16 mm or more, fix the No. 1 camshaft in place.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

Loosen the 2 union bolts.

Uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.

Remove the 2 union bolts and No. 1 and No. 2 oil feed pipes.

Remove the 8 No. 3 camshaft bearing caps and No. 1 camshaft bearing cap.

HINT:

Be sure to arrange the removed parts for each installation position separately.

Remove the No. 1 and No. 2 camshafts.

Remove the 16 No. 1 valve rocker arms.

HINT:

Be sure to arrange the removed parts for each installation position separately.

Remove the 16 No. 1 valve lash adjusters.

HINT:

Be sure to arrange the removed parts for each installation position separately.

Uniformly loosen and remove the 10 bolts and 10 spacers in the sequence shown in the illustration. Then remove the cylinder head.

NOTICE:

1. Be careful not to drop washers into the cylinder head.
   
2. Head warpage or cracking could result from removing bolts in an incorrect order.
   

HINT:

Be sure to arrange the removed parts for each installation position separately.

Using a 6 mm x 1.0 pitch service bolt with a length of 16 mm or more, fix the No. 4 camshaft in place.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

Loosen the 2 union bolts.

Uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.

Remove the 2 union bolts and No. 3 and No. 4 oil feed pipes.

Remove the 8 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap.

HINT:

Be sure to arrange the removed parts for each installation position separately.

Remove the No. 3 and No. 4 camshafts.

Remove the 16 No. 2 valve rocker arms.

HINT:

Be sure to arrange the removed parts for each installation position separately.

Remove the 16 No. 2 valve lash adjusters.

HINT:

Be sure to arrange the removed parts for each installation position separately.

Uniformly loosen and remove the 10 bolts and 10 spacers in the sequence shown in the illustration. Then remove the cylinder head.

NOTICE:

1. Be careful not to drop washers into the cylinder head.
   
2. Head warpage or cracking could result from removing bolts in an incorrect order.
   

HINT:

Be sure to arrange the removed parts for each installation position separately.

Intake Pipe:

1. Using an E8 "TORX" wrench, replace the 4 stud bolts.
   

   Torque:

   6.0 N*m{61 kgf*cm, 53 in.*lbf}

No. 3 Intake Manifold:

1. Using an E8 "TORX" wrench, replace the 2 stud bolts labeled A.
   

   Torque:

   6.0 N*m{61 kgf*cm, 53 in.*lbf}

2. Using an E6 "TORX" wrench, replace the 2 stud bolts labeled B.
   

   Torque:

   5.0 N*m{51 kgf*cm, 44 in.*lbf}

3. Using an E6 "TORX" wrench, replace the stud bolt labeled C.
   

   Torque:

   4.0 N*m{41 kgf*cm, 35 in.*lbf}

Oil Filter Bracket:

1. Using an E8 "TORX" wrench, replace the 2 stud bolts.
   

   Torque:

   6.0 N*m{61 kgf*cm, 53 in.*lbf}

No. 1 Oil Pan:

1. Using an E8 "TORX" wrench, replace the 2 stud bolts labeled A.
   

   Torque:

   6.0 N*m{61 kgf*cm, 53 in.*lbf}

2. Using an E7 "TORX" wrench, replace the 2 stud bolts labeled B.
   

   Torque:

   5.2 N*m{53 kgf*cm, 46 in.*lbf}

Timing Chain Cover:

1. Using an E7 "TORX" wrench, replace the 2 stud bolts labeled A.
   

   Torque:

   6.0 N*m{61 kgf*cm, 53 in.*lbf}

2. Replace the 2 stud bolts labeled B.
   

   Torque:

   12 N*m{120 kgf*cm, 9 ft.*lbf}

Timing Gear Case:

1. Using an E7 "TORX" wrench, replace the 4 stud bolts.
   

   Torque:

   6.0 N*m{61 kgf*cm, 53 in.*lbf}





2. Remove the 2 stud bolts.
   

3. Remove the adhesive from the threads of the timing gear case.
   

4. Apply adhesive to 2 or more threads of the 2 stud bolts.
   

5. Install the 2 stud bolts.
   

   Torque:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

No. 1 Oil Pan:

1. Using a 10 mm hexagon wrench, replace the straight screw plug and/or gasket.
   

   Torque:

   50 N*m{510 kgf*cm, 37 ft.*lbf}





2. Using a 14 mm hexagon wrench, replace the straight screw plug and/or gasket.
   

   Torque:

   86 N*m{877 kgf*cm, 63 ft.*lbf}

Oil Filter Bracket:

1. Using a 10 mm hexagon wrench, replace the straight screw plug and/or gasket.
   

   Torque:

   50 N*m{510 kgf*cm, 37 ft.*lbf}

Timing Gear Case:

1. Using a 10 mm hexagon wrench, replace the straight screw plug and/or gasket.
   

   Torque:

   40 N*m{408 kgf*cm, 30 ft.*lbf}

Replace the 2 straight screw plugs and 2 gaskets.

Torque:

38 N*m{387 kgf*cm, 28 ft.*lbf}

Text in Illustration

Front

No. 1 and No. 2 Intake Manifold:

1. Replace the ring pin.
   

   Standard protrusion:

   4.4 to 5.6 mm (0.173 to 0.222 in.)
   

   Text in Illustration

   *a	4.4 to 5.6 mm

Cylinder Head:

1. Replace the ring pin.
   

   Standard protrusion:

   4.4 to 5.6 mm (0.173 to 0.222 in.)
   

   Text in Illustration

   *a	RH
   *b	LH
   *c	4.4 to 5.6 mm

V-ribbed Belt Tensioner:

1. Replace the ring pin.
   

   Standard protrusion:

   4.7 to 5.7 mm (0.185 to 0.224 in.)
   

   Text in Illustration

   *a	4.7 to 5.7 mm

Timing Chain Case:

1. Replace the ring pin.
   

   Standard protrusion:

   4.7 to 5.7 mm (0.185 to 0.224 in.)
   

   Text in Illustration

   *a	4.7 to 5.7 mm

Timing Gear Case:

1. Replace the ring pin.
   

   Standard protrusion:

   5.2 to 5.7 mm (0.205 to 0.224 in.)
   

   Text in Illustration

   *a	5.2 to 5.7 mm

Cylinder Head RH:

1. Replace the ring pin.
   

   Standard protrusion:

   2.5 to 3.5 mm (0.0984 to 0.138 in.)
   

   Text in Illustration

   *a	No. 2 Camshaft Bearing Cap
   *b	Cylinder Head RH
   *c	2.5 to 3.5 mm

Cylinder Head LH:

1. Replace the ring pin.
   

   Standard protrusion:

   2.5 to 3.5 mm (0.0984 to 0.138 in.)
   

   Text in Illustration

   *a	No. 5 Camshaft Bearing Cap
   *b	Cylinder Head LH
   *c	2.5 to 3.5 mm

Replace the straight pin.

Standard protrusion:

18 to 20 mm (0.709 to 0.787 in.)

Replace the straight pin.

Standard protrusion:

5.0 to 7.5 mm (0.197 to 0.295 in.)

Remove the hole plug from the No. 4 camshaft.

Using a 12 mm steel bar and hammer, tap in the hole plug as shown in the illustration.

Remove the tight plug from the timing chain cover.

Apply adhesive to a new tight plug.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Using SST and a hammer, tap in the tight plug as shown in the illustration.

SST

09950-60010(09951-00550)
09950-70010(09951-07100)

Standard depth:

0.2 to 0.5 mm (0.00787 to 0.0197 in.)