Engine Course 1 Work Procedures


- 1 -
Work Procedures
Chapter Outline
This chapter explains the parts that make up the engine and explains the work procedure for engine overhaul.

ã2002 TOYOTA MOTOR CORPORATION. All right reserved.
Engine Course 1 Work Procedures


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Outline
Outline
This section will explain the required work procedures for
actually overhauling an engine. The overhaul workflow is
conducted in accordance with the following procedures.
1. Remove the engine from the vehicle
Remove the engine and transaxle as a unit from the
bottom of the vehicle.
2. Disassemble the engine
Disassemble the engine into the cylinder head and block.
3. Clean and inspect the parts
Inspect all the parts after cleaning them.
4. Reassemble the engine
Reassemble the cylinder head and block.
5. Install the engine in the vehicle
Install the engine and transaxle as a unit in the vehicle.
6. Final inspection
Make a final inspection to check assembly condition.


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Removal Engine

Outline
This section will explain operations from removal of the engine
from the vehicle to installation of the engine on the overhaul
stand.

Remove engine
Remove the engine, transaxle, suspension members, etc., as a
single unit from under the vehicle.


Engine
Transaxle
Suspension member

Drive shaft
Engine lifter
Steering gear

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REFERENCE:
When Removing Engine from Top (FR Vehicles)
When removing the engine from the top, remove the engine and
transmission as a single unit.

The following components need to be removed.
(1) Engine hood
(2) Radiator
(3) Propeller shaft
(4) Shift lever


When removing the engine, tilt and turn it while it is slung with the
chain block to prevent it from interfering with the vehicle body.

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Engine Course 1 Work Procedures


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Removal
1. Take Measures to Prevent Gasoline from Spilling Out
(1) Fuel pump connector


2. Remove Battery
(1) Battery


3. Drain Coolant
(1) Radiator cap
(2) Water drain plug
(3) Radiator drain plug


Engine Course 1 Work Procedures


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4. Disconnect Connectors and Wire Harness
(1) Engine ECU
(2) Instrument panel junction block
(3) Engine room junction block


5. Remove Vehicle Interior Components
(1) Steering intermediate shaft


6. Disconnect Clamps and Hoses
(1) Brake booster hose
(2) Radiator hose
(3) Heater hose
(4) Air cleaner hose
(5) Air cleaner


Engine Course 1 Work Procedures


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7. Disconnect Fuel Line
(1) Fuel line


8. Remove Engine Room Components
(1) Shift and select cable
(2) Clutch release cylinder
(3) A/C compressor

(4) Drive belt
(5) Engine mounting
(6) Accelerator cable


9. Remove Components from Under Vehicle
(1) Drive shaft
(2) Tie rod end
(3) Exhaust pipe
(4) Stabilizer


Engine Course 1 Work Procedures


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10. Set Engine Lifter
(1) Engine lifter


11. Remove Engine with Transaxle
(1) Engine
(2) Transaxle
(3) Suspension member
(4) Drive shaft
(5) Engine lifter


12. Disconnect Transaxle
(1) Chain block

(2) Engine sling device
(3) Engine
(4) Engine hanger


Engine Course 1 Work Procedures


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13. Remove Clutch and Flywheel
(1) Flywheel
(2) Clutch disc
(3) Clutch cover


14. Install Engine Overhaul Stand
(1) Engine
(2) Engine overhaul stand


15. Remove Intake and Exhaust Manifold, Alternator, Engine Wire
(1) Exhaust manifold heat insulator
(2) Exhaust manifold
(3) Exhaust manifold gasket
(4) Manifold support bracket
(5) Intake manifold gasket
(6) Intake manifold
(7) Alternator
(8) Engine wire


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Engine Course 1 Work Procedures


- 8 -
Disassemble Engine
Outline
This section will explain the disassembly and inspection of a
partial engine*.

1. Disassembly
Remove the timing chain and camshaft and disassemble the
cylinder head and cylinder block.

2. Inspection
Use a measuring instrument to measure the part wear. If the wear
exceeds the allowable limit, replace the part with a new one.


*Partial engine
• An engine with the auxiliary components and intake and
exhaust manifold removed.
• The largest of the engine supply states.



Partial engine
Exhaust manifold



Intake manifold

Auxiliary component (Alternator)

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Disassembly
1. Remove Water Pump Pulley
(1) Water pump pulley


Engine Course 1 Work Procedures


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2. Remove Engine Mounting Bracket
(1) Engine mounting bracket


3. Remove Crankshaft Pulley
(1) Crankshaft pulley


4. Remove Water Pump
(1) Water pump
(2) Gasket


Engine Course 1 Work Procedures



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5. Remove Timing Chain Cover
(1) Cylinder head cover
(2) Gasket
(3) Timing chain cover


6. Remove Timing Chain
(1) Chain tensioner
(2) Chain tensioner slipper
(3) Chain vibration damper
(4) Timing chain


7. Inspect Timing Chain


Vernier calipers
Timing chain
Spring balance


Pin

Bush


Engine Course 1 Work Procedures



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8. Remove Camshaft
(1) Bearing cap
(2) Camshaft


9. Inspect Camshaft Timing Gear


Vane
Housing
Lock pin
Camshaft timing gear


Oil pressure


10. Remove Camshaft Timing Gear/Sprocket
(1) Camshaft timing gear (with VVT-i)
(2) Camshaft timing sprocket (without VVT-i)


Engine Course 1 Work Procedures


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11. Remove Cylinder Head

(1) Cylinder head


12. Remove Cylinder Head Gasket
(1) Cylinder head gasket


13. Remove Oil Pan
(1) Drain plug
(2) Oil pan No.2
(3) Oil strainer
(4) Gasket
(5) Oil pan No.1


Engine Course 1 Work Procedures


- 13 -
14. Remove Oil Seal
(1) Timing chain cover oil seal
(2) Engine rear oil seal

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Cylinder Head
Outline
This section will explain cylinder head disassembly, inspection,
and reassembly.
1. Disassembly

Using SST, remove the valve.

2. Inspection
Using a measuring instrument, measure the part's warp and
wear. Replace parts that exceed limit values with new parts.

3. Reassembly
Conduct the work while checking the part's assembly position.

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Disassembly
1. Remove Valve Lifter


Valve lifter
Keeper
Valve spring retainer
Valve spring


Valve stem oil seal

Spring seat

Valve