Part 1

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

DISASSEMBLY

HINT:
^ Thoroughly clean all parts to be assembled.
^ Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
^ Replace all gaskets, O-rings and oil seals with new parts.

1. REMOVE ENGINE HANGERS
(a) Remove the 2 bolts and engine hanger No. 1.
(b) Remove the 2 bolts and engine hanger No. 2.
2. REMOVE OIL LEVEL GAGE GUIDE
(a) Remove the bolt, then pull out the oil level gauge guide.
(b) Remove the O-ring from the oil level gauge guide.
3. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Remove the 2 water drain cocks.

4. REMOVE VVT SENSOR
(a) Remove the 2 bolts, then remove the 2 VVT sensors.

5. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the bolt, then remove the crankshaft position sensor.

6. REMOVE OIL CONTROL VALVE FILTER
(a) Remove the plug and filter, then remove the gasket from each cylinder head.

7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove the 10 bolts, 3 seal washers and 2 nuts, then remove the cylinder head cover.
(b) Remove the gasket from the cylinder head cover.

8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Remove the 10 bolts, 3 seal washers and 2 nuts, then remove the cylinder head cover.
(b) Remove the gasket from the cylinder head cover.
(c) Remove the ventilation valve from the cylinder head cover.
9. REMOVE CRANKSHAFT PULLEY

(a) Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned.

(b) Check that each timing mark of the camshaft timing gears is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.

(d) Using the pulley set bolt and SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05030)
10. REMOVE OIL PAN DRAIN PLUG
(a) Remove the drain plug and gasket.
11. REMOVE NO.2 OIL PAN SUB-ASSEMBLY

(a) Remove the 15 bolts and 2 nuts (for 2WD).

(b) Remove the 10 bolts and 2 nuts (for Pre Runner and 4WD).

(c) Insert the blade of SST between the oil pan and oil pan No. 2, then cut off applied sealer and remove the oil pan No. 2.
SST 09032-00100

NOTICE:
^ Be careful not to damage the contact surface of the oil pan and oil pan No. 2.
^ Be careful not to damage the oil pan No. 2 flange.

12. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the 2 nuts, then remove the oil strainer and gasket (for 2WD).

(b) Remove the 2 nuts, then remove the oil strainer and gasket (for Pre Runner and 4WD).
13. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 17 bolts and 2 nuts (for 2WD).

(b) Remove the 17 bolts and 2 nuts (for Pre Runner and 4WD).

(c) Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block in the sequence shown.

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

(d) Remove the O-ring from the oil pump.

14. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 17 bolts, then remove the water pump and gasket.
15. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

(a) Remove the 15 bolts and 2 nuts.

(b) Remove the timing chain cover by prying between the timing chain cover, cylinder head and cylinder block with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head.

(c) Remove the O-ring from the LH cylinder head.
16. REMOVE NO.1 CHAIN TENSIONER ASSEMBLY

NOTICE:
^ Never rotate the crankshaft with the chain tensioner removed.
^ When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.

(a) While turning the stopper plate of the tensioner upward, push in the plunger of the chain tensioner as shown in the illustration.
(b) While turning the stopper plate of the tensioner downward, insert a bar of [diameter] 3.5 mm (0.138 inch) into the holes in the stopper plate and tensioner to fix the stopper plate.
(c) Remove the 2 bolts, then remove the chain tensioner.
17. REMOVE CHAIN TENSIONER SLIPPER

18. REMOVE IDLE SPROCKET ASSEMBLY
(a) Using a 10 mm hexagon wrench, remove the idle gear shaft No. 2, idle gear No. 1 and idle gear shaft No. 1.

19. REMOVE NO.2 CHAIN VIBRATION DAMPER
(a) Remove the 2 chain vibration dampers No. 2.
20. REMOVE CHAIN SUB-ASSEMBLY
21. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET

22. REMOVE NO.1 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts, then remove the chain vibration damper No. 1.
23. REMOVE CAMSHAFT TIMING GEARS AND NO.2 CHAIN (for Bank 1)

(a) While raising the chain tensioner No. 2 upward, insert a pin of [diameter] 1.0 mm (0.039 inch) into the hole to fix it.

(b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and timing chain No. 2.

NOTICE:
^ Be careful not to damage the cylinder head and valve lifter with the wrench.
^ Do not disassemble the camshaft timing gear assembly.

24. REMOVE NO.2 CHAIN TENSIONER ASSEMBLY
(a) Remove the bolt, then remove the chain tensioner No. 2.
25. REMOVE CAMSHAFT TIMING GEARS AND NO.2 CHAIN (for Bank 2)

(a) While pushing down the chain tensioner No. 3, insert a pin of [diameter] 1.0 mm (0.039 inch) into the hole to fix it.