Toyota Corolla Cross: Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

COMPONENTS (DISASSEMBLY)

Procedure		Part Name Code
1	SPARK PLUG	19100P		-	-
2	KNOCK CONTROL SENSOR	89615		-	-
3	OIL PRESSURE AND TEMPERATURE SENSOR	89448D		-	-
4	OIL PRESSURE CONTROL VALVE ASSEMBLY	15250		-	-
5	CAM TIMING OIL CONTROL SOLENOID ASSEMBLY	15370		-	-
6	CAM TIMING OIL CONTROL SOLENOID O-RING	13090E		-	-
7	CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY	13090D		-	-
8	CAM TIMING CONTROL MOTOR O-RING	13090E	-	-	-
9	OIL FILLER CAP ASSEMBLY	12180E	-	-	-
10	OIL FILLER CAP GASKET	12108A	-	-	-
11	CRANKSHAFT POSITION SENSOR	11401G		-	-
12	PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)	12204C	-	-	-
13	VACUUM PUMP ASSEMBLY	29300		-	-

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Non-reusable part

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Precoated part

Procedure		Part Name Code
14	CRANKSHAFT PULLEY ASSEMBLY	13470		-	-
15	WATER OUTLET	16331		-	-
16	WATER OUTLET GASKET	16341	-	-	-
17	WATER BY-PASS OUTLET SUB-ASSEMBLY	16305E		-	-
18	WATER OUTLET PIPE GASKET	16345	-	-	-
19	CAMSHAFT POSITION SENSOR (for Intake Side)	11102A		-	-
20	CAMSHAFT POSITION SENSOR (for Exhaust Side)	11102A		-	-
21	CYLINDER HEAD COVER SUB-ASSEMBLY	11201		-	-
22	SPARK PLUG TUBE GASKET	11193		-	-
23	ENGINE MOUNTING BRACKET RH	12315A	-	-	-
24	STRAIGHT SCREW PLUG	-		-	-
25	NO. 2 TIMING CHAIN COVER ASSEMBLY	11320B		-	-
26	TIMING CHAIN COVER OIL SEAL	11301C		-	-

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Non-reusable part

★

Precoated part

Procedure		Part Name Code
27	NO. 1 CYLINDER TO TDC (COMPRESSION)	-		-	-
28	CHAIN TENSIONER PLATE	-	-	-	-
29	OIL PUMP DRIVE CHAIN SUB-ASSEMBLY	13507A		-	-
30	CAMSHAFT TIMING GEAR ASSEMBLY	13050		-	-
31	CHAIN SUB-ASSEMBLY	13506	-	-	-
32	CRANKSHAFT TIMING SPROCKET	13521	-	-	-
33	NO. 1 CHAIN TENSIONER ASSEMBLY	13540		-	-
34	CHAIN TENSIONER SLIPPER	13559	-	-	-
35	NO. 1 CHAIN VIBRATION DAMPER	13561	-	-	-
36	CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY	13070A		-	-
37	TIMING CHAIN COVER ASSEMBLY	11310		-	-
38	OIL NOZZLE VALVE SUB-ASSEMBLY	15703A	-	-	-
39	CRANKSHAFT TIMING GEAR KEY	13471A		-	-

Procedure		Part Name Code
40	FUEL PUMP LIFTER GUIDE	23477		-	-
41	CAMSHAFT HOUSING SUB-ASSEMBLY	11103		-	-
42	CAMSHAFT BEARING CAP	-		-	-
43	INTAKE CAMSHAFT SUB-ASSEMBLY	13501A	-	-	-
44	EXHAUST CAMSHAFT SUB-ASSEMBLY	13502B	-	-	-
45	NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY	13801	-	-	-
46	VALVE LASH ADJUSTER ASSEMBLY	13750	-	-	-
47	VALVE STEM CAP	13716	-	-	-
48	WATER SEAL PLATE	11492B		-	-
49	WATER SEAL PLATE GASKET	11493A	-	-	-
50	CYLINDER HEAD SUB-ASSEMBLY	11101		-	-
51	CYLINDER HEAD GASKET	11115	-	-	-
52	CYLINDER BLOCK WATER JACKET SPACER	11445		-	-

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Non-reusable part

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Procedure		Part Name Code
53	OIL FILTER SUB-ASSEMBLY	15601	-	-	-
54	OIL FILTER UNION	15600A		-	-
55	OIL PAN DRAIN PLUG	12101A	-	-	-
56	OIL PAN SUB-ASSEMBLY	12101		-	-
57	OIL STRAINER SUB-ASSEMBLY	15104		-	-
58	ENGINE OIL LEVEL SENSOR	89491		-	-
59	OIL PUMP ASSEMBLY	15100		-	-
60	STIFFENING CRANKCASE ASSEMBLY	11420		-
61	STRAIGHT SCREW PLUG	-		-	-
62	REAR ENGINE OIL SEAL	11401L		-	-
63	WIRE HARNESS CLAMP BRACKET	-	-	-	-

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Non-reusable part

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-

Procedure		Part Name Code
64	STUD BOLT	-		-	-
65	RING PIN	-		-	-
66	STRAIGHT PIN	-		-	-

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Non-reusable part

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CAUTION / NOTICE / HINT

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during electric power steering column sub-assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Replacement of cylinder head sub-assembly Replacement of camshaft (for intake or exhaust camshaft) Replacement of camshaft timing gear assembly Replacement of spark plug	Inspection After Repair	Poor idle, etc. Engine start function, etc.

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. REMOVE SPARK PLUG

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2. REMOVE KNOCK CONTROL SENSOR

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3. REMOVE OIL PRESSURE AND TEMPERATURE SENSOR

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4. REMOVE OIL PRESSURE CONTROL VALVE ASSEMBLY

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5. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

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6. REMOVE CAM TIMING OIL CONTROL SOLENOID O-RING

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7. REMOVE CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

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8. REMOVE CAM TIMING CONTROL MOTOR O-RING

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9. REMOVE OIL FILLER CAP ASSEMBLY

10. REMOVE OIL FILLER CAP GASKET

11. REMOVE CRANKSHAFT POSITION SENSOR

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12. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)

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13. REMOVE VACUUM PUMP ASSEMBLY

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14. REMOVE CRANKSHAFT PULLEY ASSEMBLY

*1	Crankshaft Pulley Bolt	-	-
*a	Hold	*b	Turn
	Turn	-	-

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

SST: 09213-54015

SST: 09330-00021

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

SST: 09950-50013

09951-05010

09952-05010

09953-05020

09954-05070

09957-04010

HINT:

Apply lubricant to the threads and end of SST.

15. REMOVE WATER OUTLET

(1) Using an 8 mm socket wrench, remove the 2 bolts, water outlet and water outlet gasket from the cylinder head sub-assembly.

16. REMOVE WATER OUTLET GASKET

17. REMOVE WATER BY-PASS OUTLET SUB-ASSEMBLY

(1) Using an 8 mm socket wrench, remove the 3 bolts, water by-pass outlet sub-assembly and water pipe outlet gasket from the cylinder head sub-assembly.

18. REMOVE WATER OUTLET PIPE GASKET

19. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

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20. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

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21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(1) Using an 8 mm socket wrench, remove the 16 bolts and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

(2) Remove the 7 cylinder head cover gaskets from the cylinder head cover sub-assembly.

(3) Remove the camshaft bearing cap oil hole gasket from the No. 1 camshaft bearing cap.

22. REMOVE SPARK PLUG TUBE GASKET

(1) Using a screwdriver, pry out the 4 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.

23. REMOVE ENGINE MOUNTING BRACKET RH

24. REMOVE STRAIGHT SCREW PLUG

(1) Using a 10 mm hexagon wrench, remove the straight screw plug from the No. 2 timing chain cover assembly.

25. REMOVE NO. 2 TIMING CHAIN COVER ASSEMBLY

(1) Remove the 20 bolts.

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

NOTICE:

Be careful not to damage the contact surfaces of the No. 2 timing chain cover assembly and timing chain cover assembly.

26. REMOVE TIMING CHAIN COVER OIL SEAL

(1) Using a screwdriver and wooden block, pry out the timing chain cover oil seal.

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

27. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

(1) Temporarily install the crankshaft pulley bolt.

*1	Crankshaft Timing Gear Key	-	-
*a	Approximately 4.63°	*b	Approximately 33.07°
*c	Approximately 2.73°	*d	Timing Mark

(1) Rotate the crankshaft clockwise and align the crankshaft timing gear key as shown in the illustration.

(2) Check that the timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.

(1) Remove the crankshaft pulley bolt.

HINT:

As the exhaust camshaft sub-assembly may rotate counterclockwise strongly when the crankshaft pulley bolt is removed, use a wrench to hold the hexagonal portion of the exhaust camshaft sub-assembly.

28. REMOVE CHAIN TENSIONER PLATE

*1

Chain Tensioner Plate

*2

Chain Damper Spring

29. REMOVE OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

*1	Oil Pump Drive Chain Sub-assembly	*2	Oil Pump Drive Sprocket
*3	Oil Pump Drive Shaft Sprocket	-	-

30. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

*a	Loosen	*b	Hold
	Turn	-	-

(1) Hold the hexagonal portion of the exhaust camshaft sub-assembly with a wrench and turn it clockwise to loosen the chain sub-assembly between the camshaft timing exhaust gear assembly and camshaft timing gear assembly.

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

NOTICE:

• Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube with the wrench.
• Do not disassemble the camshaft timing gear assembly.

(3) Using a 10 mm bi-hexagonal wrench, remove the bolt and camshaft timing gear assembly from the intake camshaft sub-assembly.

31. REMOVE CHAIN SUB-ASSEMBLY

32. REMOVE CRANKSHAFT TIMING SPROCKET

33. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(1) Using an 8 mm socket wrench, remove the bolt.

(2) Remove the nut and No. 1 chain tensioner assembly from the timing chain cover assembly.

NOTICE:

Make sure that the plunger, check ball assembly and spring do not come out.

*a	Tape	*b	Plunger
*c	Check ball assembly	*d	Spring
*e	No. 1 chain tensioner assembly body	-	-

(1) Use tape to hold the plunger inside the No. 1 chain tensioner assembly.

NOTICE:

• Make sure that the plunger, check ball assembly and spring do not come out.
• If the No. 1 chain tensioner assembly comes apart, reinstall the parts as shown in the illustration.

34. REMOVE CHAIN TENSIONER SLIPPER

35. REMOVE NO. 1 CHAIN VIBRATION DAMPER

36. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

*1

Camshaft Timing Exhaust Gear Assembly

*2

Camshaft Timing Oil Control Valve Assembly (Exhaust Camshaft Timing Gear Bolt Assembly)

(1) 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.

(2) Using a 5 mm hexagon socket wrench, remove the 3 bolts.

(3) 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.

37. REMOVE TIMING CHAIN COVER ASSEMBLY

(1) Remove the 20 bolts and timing chain cover assembly from the camshaft housing sub-assembly, cylinder head sub-assembly, cylinder block sub-assembly, stiffening crankcase assembly and oil pump assembly.

(2) Remove the timing chain cover assembly by prying between the cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly, oil pump assembly and stiffening crankcase assembly with a screwdriver with its tip wrapped with protective tape.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-assembly, stiffening crankcase assembly, oil pump assembly and timing chain cover assembly.

38. REMOVE OIL NOZZLE VALVE SUB-ASSEMBLY

39. REMOVE CRANKSHAFT TIMING GEAR KEY

(1) Using a screwdriver with its tip wrapped in protective tape, remove the 2 crankshaft timing gear keys from the crankshaft.

40. REMOVE FUEL PUMP LIFTER GUIDE

(1) Using an 8 mm socket wrench, remove the 2 bolts and fuel pump lifter guide from the No. 4 camshaft bearing cap.

41. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

(1) Uniformly loosen and remove the 17 bolts in the order shown in the illustration.

(2) Using a screwdriver, remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly at the places shown in the illustration.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head sub-assembly and camshaft housing sub-assembly.

HINT:

Tape the screwdriver tip before use.

42. REMOVE CAMSHAFT BEARING CAP

*1	No. 1 Camshaft Bearing Cap	*2	No. 2 Camshaft Bearing Cap
*3	No. 3 Camshaft Bearing Cap	*4	No. 4 Camshaft Bearing Cap

(1) Uniformly loosen and remove the 9 bolts in the order shown in the illustration.

(2) Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 2 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap from the camshaft housing sub-assembly.

HINT:

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

43. REMOVE INTAKE CAMSHAFT SUB-ASSEMBLY

44. REMOVE EXHAUST CAMSHAFT SUB-ASSEMBLY

45. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

46. REMOVE VALVE LASH ADJUSTER ASSEMBLY

47. REMOVE VALVE STEM CAP

48. REMOVE WATER SEAL PLATE

(1) Using an 8 mm socket wrench, remove the 2 bolts, water seal plate and gasket from the cylinder head sub-assembly.

49. REMOVE WATER SEAL PLATE GASKET

50. REMOVE CYLINDER HEAD SUB-ASSEMBLY

*a	Plate Washer	-	-
	Front of Engine	-	-

(1) Using a 12 mm socket wrench, uniformly loosen the 10 cylinder head set bolts in the order shown in the illustration. Remove the 10 cylinder head set bolts and 6 plate washers.

NOTICE:

• Be careful not to drop the plate washers into the cylinder head sub-assembly.
• Warpage or cracking of the cylinder head sub-assembly may result from removing the cylinder head set bolts in the incorrect order.

HINT:

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

(2) Remove the cylinder head sub-assembly from the cylinder block sub-assembly.

51. REMOVE CYLINDER HEAD GASKET

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52. REMOVE CYLINDER BLOCK WATER JACKET SPACER

NOTICE: Be sure to remove the cylinder block water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block sub-assembly is inverted.

53. REMOVE OIL FILTER SUB-ASSEMBLY

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54. REMOVE OIL FILTER UNION

(1) Using a 12 mm hexagon socket wrench, remove the oil filter union from the stiffening crankcase assembly.

55. REMOVE OIL PAN DRAIN PLUG

56. REMOVE OIL PAN SUB-ASSEMBLY

*a

Nut

-

-

(1) Remove the 10 bolts and 2 nuts.

(2) 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.

NOTICE:

• Be careful not to damage the contact surfaces of the stiffening crankcase assembly and oil pan sub-assembly.
• Be careful not to damage the oil pan sub-assembly flange.

57. REMOVE OIL STRAINER SUB-ASSEMBLY

(1) Using an 8 mm socket wrench, remove the bolt, oil strainer sub-assembly and oil strainer gasket from the stiffening crankcase assembly.

58. REMOVE ENGINE OIL LEVEL SENSOR

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59. REMOVE OIL PUMP ASSEMBLY

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60. REMOVE STIFFENING CRANKCASE ASSEMBLY

(1) Remove the 10 bolts.

(2) Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly at the places shown in the illustration.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder block sub-assembly and stiffening crankcase assembly.

HINT:

Tape the screwdriver tip before use.

61. REMOVE STRAIGHT SCREW PLUG

(1) Using a 10 mm hexagon socket wrench, remove the straight screw plug and gasket from the stiffening crankcase assembly.

62. REMOVE REAR ENGINE OIL SEAL

63. REMOVE WIRE HARNESS CLAMP BRACKET

64. REMOVE STUD BOLT

NOTICE: If a stud bolt is deformed or its threads are damaged, replace it.

65. REMOVE RING PIN

NOTICE: It is not necessary to remove the ring pins unless they are being replaced.

66. REMOVE STRAIGHT PIN

NOTICE: It is not necessary to remove the straight pins unless they are being replaced.

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