Toyota Corolla Cross: Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

NOTICE:

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

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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	CAMSHAFT POSITION SENSOR (for Intake Side)	11102A		-	-
6	CAMSHAFT POSITION SENSOR (for Exhaust Side)	11102A		-	-
7	CAM TIMING OIL CONTROL SOLENOID ASSEMBLY	15370		-	-
8	CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY	13090D		-	-
9	CAM TIMING CONTROL MOTOR O-RING	13090E	-	-	-
10	OIL FILLER CAP ASSEMBLY	12180E	-	-	-
11	OIL FILLER CAP GASKET	12108A	-	-	-
12	CRANKSHAFT POSITION SENSOR	11401G		-	-
13	PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY)	12204C	-	-	-

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Non-reusable part

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Precoated part

Procedure		Part Name Code
14	CRANKSHAFT PULLEY ASSEMBLY	13470		-	-
15	INLET HEATER WATER HOSE	-	-	-	-
16	OUTLET HEATER WATER HOSE	-	-	-	-
17	WATER OUTLET SUB-ASSEMBLY	16304	-	-	-
18	WATER BY-PASS OUTLET	16351		-	-
19	CYLINDER HEAD COVER SUB-ASSEMBLY	11201		-	-
20	SPARK PLUG TUBE GASKET	11193		-	-
21	ENGINE MOUNTING BRACKET RH	12315A	-	-	-
22	STRAIGHT SCREW PLUG	-		-	-
23	NO. 2 TIMING CHAIN COVER ASSEMBLY	11320B		-	-
24	TIMING CHAIN COVER OIL SEAL	11301C		-	-
25	NO. 1 CYLINDER TO TDC (COMPRESSION)	-		-	-

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Non-reusable part

★

Precoated part

Procedure		Part Name Code
26	OIL PUMP DRIVE CHAIN SUB-ASSEMBLY	13507A		-	-
27	CAMSHAFT TIMING GEAR ASSEMBLY	13050		-	-
28	CHAIN SUB-ASSEMBLY	13506	-	-	-
29	NO. 1 CHAIN TENSIONER ASSEMBLY	13540		-	-
30	CHAIN TENSIONER SLIPPER	13559	-	-	-
31	NO. 1 CHAIN VIBRATION DAMPER	13561	-	-	-
32	CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY	13070A		-	-
33	TIMING CHAIN COVER ASSEMBLY	11310		-	-
34	OIL NOZZLE VALVE SUB-ASSEMBLY	15703A	-	-	-
35	CRANKSHAFT TIMING GEAR KEY	13471A		-	-

*1	CRANKSHAFT TIMING SPROCKET	*2	OIL PUMP DRIVE SPROCKET
*3	OIL PUMP DRIVE SHAFT SPROCKET	*4	CHAIN TENSIONER PLATE
*5	CHAIN DAMPER SPRING	-	-

Procedure		Part Name Code
36	FUEL PUMP LIFTER GUIDE	23477		-	-
37	CAMSHAFT HOUSING SUB-ASSEMBLY	11103		-	-
38	CAMSHAFT BEARING CAP	-		-	-
39	INTAKE CAMSHAFT SUB-ASSEMBLY	13501A	-	-	-
40	EXHAUST CAMSHAFT SUB-ASSEMBLY	13502B	-	-	-
41	NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY	13801		-	-
42	VALVE LASH ADJUSTER ASSEMBLY	13750		-	-
43	VALVE STEM CAP	13716		-	-
44	NO. 1 WATER BY-PASS PIPE	16268		-	-
45	CYLINDER HEAD SUB-ASSEMBLY	11101		-	-
46	CYLINDER HEAD GASKET	11115	-	-	-

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Non-reusable part

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-

Procedure		Part Name Code
47	CYLINDER BLOCK WATER JACKET SPACER	11445		-	-
48	OIL FILTER SUB-ASSEMBLY	15601	-	-	-
49	OIL FILTER UNION	15600A		-	-
50	OIL PAN DRAIN PLUG	12101A	-	-	-
51	OIL PAN SUB-ASSEMBLY	12101		-	-
52	OIL STRAINER SUB-ASSEMBLY	15104		-	-
53	ENGINE OIL LEVEL SENSOR	89491		-	-
54	ENGINE BALANCER ASSEMBLY	-		-	-
55	OIL PUMP ASSEMBLY	15100	-	-	-
56	STIFFENING CRANKCASE ASSEMBLY	11420		-	-
57	STRAIGHT SCREW PLUG	-		-	-

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Non-reusable part

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-

Procedure		Part Name Code
58	STUD BOLT	-		-	-
59	RING PIN	-		-	-
60	STRAIGHT PIN	-		-	-
61	REAR ENGINE OIL SEAL	11401L	-	-	-

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Non-reusable part

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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 CAMSHAFT POSITION SENSOR (for Intake Side)

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6. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

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7. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

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8. REMOVE CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

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9. REMOVE CAM TIMING CONTROL MOTOR O-RING

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10. REMOVE OIL FILLER CAP ASSEMBLY

11. REMOVE OIL FILLER CAP GASKET

12. REMOVE CRANKSHAFT POSITION SENSOR

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

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14. REMOVE CRANKSHAFT PULLEY ASSEMBLY

*1	Crankshaft Pulley Bolt	-	-
*a	Hold	*b	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 INLET HEATER WATER HOSE

16. REMOVE OUTLET HEATER WATER HOSE

17. REMOVE WATER OUTLET SUB-ASSEMBLY

18. REMOVE WATER BY-PASS OUTLET

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

19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(1) Using an 8 mm socket wrench, remove the 4 bolts (A).

(2) Remove the 12 bolts (B) and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

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

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

20. 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.

21. REMOVE ENGINE MOUNTING BRACKET RH

22. REMOVE STRAIGHT SCREW PLUG

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

23. REMOVE NO. 2 TIMING CHAIN COVER ASSEMBLY

(1) Remove the 20 bolts.

(1) 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.

24. REMOVE TIMING CHAIN COVER OIL SEAL

*a

Wooden Block

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-

(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.

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

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

(1) Temporarily install the crankshaft pulley bolt.

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

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

(4) 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.

26. REMOVE OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

*1	Chain Tensioner Plate	*2	Chain Damper Spring
*3	Oil Pump Drive Chain Sub-assembly	*4	Oil Pump Drive Sprocket
*5	Oil Pump Drive Shaft Sprocket	-	-
*a	Bolt	-	-

(1) Temporarily install the crankshaft pulley assembly with the crankshaft pulley bolt.

(2) While holding the crankshaft pulley assembly with SST, remove the bolt.

SST: 09213-54015

SST: 09330-00021

(3) Remove SST, the crankshaft pulley bolt and crankshaft pulley assembly.

(4) Remove the chain tensioner plate and chain damper spring.

(5) Remove the oil pump drive sprocket, oil pump drive shaft sprocket and oil pump drive chain sub-assembly.

27. 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 the camshaft timing gear assembly 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.

28. REMOVE CHAIN SUB-ASSEMBLY

29. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

*a

Tape

-

-

(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.

(3) 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.

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

30. REMOVE CHAIN TENSIONER SLIPPER

31. REMOVE NO. 1 CHAIN VIBRATION DAMPER

32. 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 and 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.

33. 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.

(1) Remove the timing chain cover assembly by prying between the cylinder head sub-assembly, camshaft housing sub-assembly, cylinder block sub-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 and timing chain cover assembly.

34. REMOVE OIL NOZZLE VALVE SUB-ASSEMBLY

35. REMOVE CRANKSHAFT TIMING GEAR KEY

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

HINT:

Tape the screwdriver tip before use.

36. 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.

37. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

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

(2) Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver.

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.

38. 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) 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.

39. REMOVE INTAKE CAMSHAFT SUB-ASSEMBLY

40. REMOVE EXHAUST CAMSHAFT SUB-ASSEMBLY

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

(1) Remove the 16 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.

42. REMOVE VALVE LASH ADJUSTER ASSEMBLY

(1) Remove the 16 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.

43. REMOVE VALVE STEM CAP

(1) Remove the 16 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.

44. REMOVE NO. 1 WATER BY-PASS PIPE

(1) Using an 8 mm socket wrench, remove the 2 bolts, No. 1 water by-pass pipe and water by-pass pipe gasket from the cylinder head sub-assembly.

45. REMOVE CYLINDER HEAD SUB-ASSEMBLY

Front of Engine

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-

(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.

46. REMOVE CYLINDER HEAD GASKET

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47. REMOVE CYLINDER BLOCK WATER JACKET SPACER

(1) Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.

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.

48. REMOVE OIL FILTER SUB-ASSEMBLY

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49. REMOVE OIL FILTER UNION

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

50. REMOVE OIL PAN DRAIN PLUG

51. REMOVE OIL PAN SUB-ASSEMBLY

*a

Nut

-

-

(1) Remove the 12 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.

52. 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.

53. REMOVE ENGINE OIL LEVEL SENSOR

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54. REMOVE ENGINE BALANCER ASSEMBLY

(1) Remove the 6 bolts and engine balancer assembly from the stiffening crankcase assembly.

NOTICE:

Do not disassemble the engine balancer assembly.

55. REMOVE OIL PUMP ASSEMBLY

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56. REMOVE STIFFENING CRANKCASE ASSEMBLY

(1) Remove the 7 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.

57. REMOVE STRAIGHT SCREW PLUG

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

58. REMOVE STUD BOLT

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

59. REMOVE RING PIN

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

60. REMOVE STRAIGHT PIN

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

61. REMOVE REAR ENGINE OIL SEAL

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