Toyota Yaris: Engine Unit / Disassembly

(a) Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.

(a) Remove the oil filler cap gasket from the oil filler cap sub-assembly.

(a) Using SST, hold the crankshaft pulley assembly and loosen the crankshaft pulley set bolt. Further loosen the crankshaft pulley set bolt until 2 or 3 threads remain screwed into the crankshaft.

SST: 09213-54015

SST: 09330-00021

(b) Using SST and the crankshaft pulley set bolt, remove the crankshaft pulley assembly and crankshaft pulley set bolt.

SST: 09950-50013

09951-05010

09952-05010

09953-05020

09954-05070

09957-04010

HINT:

Apply lubricant to the threads and end of SST.

(a) Remove the 2 nuts, outlet water sub-aseembly and water outlet gasket from the cylinder head sub-assembly.

(a) Remove the 17 bolts and cylinder head cover sub-assembly from the cylinder head sub-assembly.

(b) Remove the 5 cylinder head cover gaskets from the cylinder head cover sub-assembly.

(c) Remove the 2 camshaft bearing cap oil hole gaskets from the No. 1 camshaft bearing cap and fuel pump lifter housing.

(a) Using a screwdriver, pry out the 3 spark plug tube gaskets from the cylinder head cover sub-assembly.

NOTICE:

Be careful not to damage the cylinder head cover sub-assembly.

HINT:

Tape the screwdriver tip before use.

(a) Remove the 4 bolts and No. 1 vacuum pump bracket from the cylinder head sub-assembly.

(a) Remove the 3 bolts and engine mounting bracket RH from the No. 2 timing chain cover assembly.

(a) Remove the 8 bolts.

(b) Remove the No. 2 timing chain cover assembly from the cylinder head sub-assembly by prying the No. 2 timing chain cover assembly with a screwdriver with its tip wrapped with protective tape.

(b) Rotate the crankshaft clockwise and make sure that the timing mark of the camshaft timing gear assembly and camshaft timing exhaust gear assembly is at the top.

(c) Check that the crankshaft timing gear key as shown in the illustration.

(a) Turn the stopper plate of the No. 1 chain tensioner assembly clockwise to release the lock and push in the plunger.

(c) Turn the stopper plate clockwise to set the lock, and insert a pin into the stopper plate hole.

(d) Remove the 2 bolts and No. 1 chain tensioner assembly from the cylinder block sub-assembly.

(e) Remove the chain tensioner gasket from the No. 1 chain tensioner assembly.

(a) Remove the 2 nut and timing chain guide from the damper plate spacer.

(a) Remove the damper plate spacer from the No. 1 camshaft bearing cap.

(a) Remove the bolt and chain tensioner slipper from the cylinder head sub-assembly.

(a) Remove the chain sub-assembly.

(a) Remove the 2 bolts and No. 1 chain vibration damper from the timing chain cover assembly.

(a) Remvoe the crankshaft timing gear or sprocket from the crankshaft.

(a) Using a screwdriver, remove the 2 crankshaft timing gear keys from the crankshaft.

HINT:

Tape the screwdriver tip before use.

(a) Using a wrench, hold the hexagonal portion of the exhaust camshaft sub-assembly.

NOTICE:

Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly or spark plug tube with the wrench.

(c) Remove the camshaft timing exhaust gear assembly and camshaft timing oil control valve assembly (exhaust camshaft timing gear bolt assembly) from the exhaust camshaft sub-assembly.

(a) Using a wrench, hold the hexagonal portion of the intake camshaft sub-assembly.

NOTICE:

Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

(c) Remove the camshaft timing gear assembly and camshaft timing oil control valve assembly (camshaft timing gear bolt assembly) from the intake camshaft sub-assembly.

(a) Remove the 2 bolts and fuel pump lifter guide from the fuel pump lifter housing.

(a) Remove the 3 bolts and fuel pump lifter housing from the cylinder head sub-aseembly.

(a) Remove the bolt and camshaft position sensor holder from the cylinder head sub-assembly.

(a) Remove the 16 bolts.

(a) Remove the exhaust camshaft sub-assembly from the camshaft housing sub-assembly.

(a) Remove the intake camshaft sub-assembly from the camshaft housing sub-assembly.

(a) Remove the No. 1 camshaft bearing cap from the cylinder head sub-assembly.

(a) Remove the 12 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

(a) Remove the 12 valve lash adjuster assemblies from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

(a) Remove the 12 valve stem caps from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

(a) Using a 12 mm socket wrench, uniformly loosen the 8 cylinder head set bolts in the order shown in the illustration. Remove the 8 cylinder head set bolts and 8 plate washers.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

(a) Remvoe the 3 bolts and oil filter bracket sub-assembly from the cylinder block sub-aseembly.

(b) Remove the 2 gaskets.

(a) Remove the oil pan drain plug and gasket from the No. 2 oil pan sub-assembly.

(a) Remove the 10 bolts and 2 nuts.

(b) Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut through the applied sealer and remove the oil pan sub-assembly.

(a) Using a 10 mm hexagon socket wrench, remove the 2 No. 1 oil pan plugs and 2 gaskets from the oil pan sub-assembly.

(a) Remove the 13 bolts and oil pan sub-aseembly from the crankshaft bearing cap assembly.

(a) Remove the 2 bolts, oil strainer sub-assembly and oil strainer gasket from the cylinder block sub-assembly.

(a) Remove the 4 bolts and engine balancer assembly from the cylinder block sub-assembly.

(a) Remove the balanceshaft housing spacer from the cylinder block sub-assembly.