Engine Unit: Disassembly

WARNING: This page is about a different car, the 2008 Lexus RX 350. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE, 2GR-FSE, 3GR-FSE, 4GR-FSE VALVE TIMING PROCEDURE .

REMOVE OIL FILLER CAP SUB-ASSEMBLY
1. Remove the oil filler cap and gasket.
REMOVE SPARK PLUG
1. Remove the spark plugs.
REMOVE OIL PAN DRAIN PLUG
1. Remove the drain plug and gasket.
  
  Fig 1: Identifying Oil Pan Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VENTILATION VALVE SUB-ASSEMBLY
1. Remove the ventilation valve.
  
  Fig 2: Identifying Ventilation Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT POSITION SENSOR
1. Remove the 4 bolts and 4 sensors.
  
  Fig 3: Identifying Camshaft Position Sensor Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Remove the 4 bolts and 4 oil control valves.
  
  Fig 4: Identifying Camshaft Timing Oil Control Valves & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT POSITION SENSOR
1. Remove the bolt and sensor.
  
  Fig 5: Identifying Crankshaft Position Sensor Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 OIL PIPE
1. Remove the 2 oil pipe unions and oil pipe.
  
  Fig 6: Identifying No. 1 Oil Pipe Unions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the oil control valve filter LH and gaskets.
REMOVE OIL PIPE
1. Remove the bolt.
2. Remove the 2 oil pipe unions and oil pipe.
  
  Fig 7: Identifying Oil Pipe Unions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the oil control valve filter RH and gaskets.
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Remove the water drain cocks from the cylinder block.
  
  Fig 8: Identifying Water Drain Cock Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the water drain cock plugs from the water drain cocks.
REMOVE OIL FILTER ELEMENT
1. Remove the drain plug.
  
  Fig 9: Identifying Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not remove the O-ring from the oil filter cap.
2. Connect the hose to the pipe.
  
  Fig 10: Connecting Hose To Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Insert the pipe with the hose into the oil filter cap.
4. Make sure that the oil is completely drained and remove the pipe and O-ring.
5. Using SST, remove the oil filter cap.
  SST 09228-06501
  
  Fig 11: Using SST To Remove Oil Filter Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the oil filter element and O-ring from the oil filter cap.
  
  Fig 12: Identifying Oil Filter Element & O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.
REMOVE CRANKSHAFT PULLEY
1. Using SST, loosen the crankshaft pulley bolt.
  SST 09213-70011 (09213-70020), 09330-00021
  
  Fig 13: Using SST To Loosen Crankshaft Pulley Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the crankshaft pulley bolt and crankshaft pulley.
  SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
  
  Fig 14: Using SST To Remove Crankshaft Pulley Bolt & Crankshaft Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler)
1. Remove the bolt, 2 clamps, and 4 clips and disconnect the 2 water by-pass hoses.
  
  Fig 15: Identifying Water By-Pass Hoses Bolt, Clamps & Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the union bolt, oil cooler assembly, and O-ring.
  
  Fig 16: Identifying Union Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)
1. Remove the 3 bolts, 3 nuts, and oil cooler pipe with No. 1 oil cooler bracket.
  
  Fig 17: Identifying No. 1 Oil Cooler Bracket Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bolt, 2 nuts, No. 1 oil cooler bracket, and gasket.
  
  Fig 18: Identifying No. 1 Oil Cooler Bracket Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a "torx" socket wrench E8, remove the 2 stud bolts.
REMOVE FRONT ENGINE MOUNTING BRACKET NO. 1 LH
1. Remove the 6 bolts and engine mounting bracket.
  
  Fig 19: Identifying Front Engine Mounting Bracket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a "torx" socket wrench E8, remove the 2 stud bolts.
REMOVE WATER INLET HOUSING
1. Remove the 2 nuts, water inlet and thermostat.
  
  Fig 20: Identifying Water Inlet Housing Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gasket.
3. Remove the drain cock plug.
4. Remove the drain cock.
5. Remove the 2 stud bolts.
6. Separate the No. 1 water by-pass hose.
7. Remove the 2 bolts, nut, and water inlet housing.
  
  Fig 21: Identifying Water Inlet Housing Bolts & Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the 2 O-rings.
  
  Fig 22: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER OUTLET
1. Remove the 2 bolts, 4 nuts and water outlet.
  
  Fig 23: Identifying Water Outlet Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 gaskets and O-ring.
  
  Fig 24: Identifying Gaskets & O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
1. Remove the 12 bolts, seal washer, head cover and gasket.
  
  Fig 25: Identifying Cylinder Head Cover Bolts (For Bank 1)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 gaskets.
  
  Fig 26: Identifying Cylinder Head Cover Gaskets (For Bank 1)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
1. Remove the 12 bolts, seal washer, head cover and gasket.
  
  Fig 27: Identifying Cylinder Head Cover Bolts (For Bank 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: The baffle plate is located on the back of the portion. Do not damage the baffle plate when removing the head cover.
2. Remove the 3 gaskets.
  
  Fig 28: Identifying Cylinder Head Cover Gaskets (For Bank 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
1. Remove the 16 bolts and 2 nuts.
  
  Fig 29: Identifying No. 2 Oil Pan Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.
  SST 09032-00100
  
  Fig 30: Removing No. 2 Oil Pan Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the contact surfaces of the oil pans.
3. Using a "torx" socket wrench E6, remove the 2 stud bolts.
REMOVE OIL STRAINER SUB-ASSEMBLY
1. Remove the bolt, 2 nuts, oil strainer and gasket.
2. Using a "torx" socket wrench E6, remove the 2 stud bolts.
  
  Fig 31: Identifying Oil Strainer Bolt & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PAN SUB-ASSEMBLY
1. Remove the 16 bolts and 2 nuts.
  
  Fig 32: Identifying Oil Pan Sub-Assembly Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.
2. Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.
  
  Fig 33: Prying Between Oil Pan & Cylinder Block With Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.
  
  HINT:
  
  Tape the screwdriver tip before use.
3. Remove the 2 O-rings.
  
  Fig 34: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a "torx" socket wrench E8, remove the 2 stud bolts, (without oil cooler)
5. Using a "torx" socket wrench E8, remove the 4 stud bolts, (with oil cooler)
REMOVE OIL PAN BAFFLE PLATE
1. Remove the 7 bolts and baffle plate.
  
  Fig 35: Identifying Oil Pan Baffle Plate Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE REAR OIL SEAL RETAINER
1. Remove the 6 bolts.
  
  Fig 36: Identifying Engine Rear Oil Seal Retainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, pry out the oil seal retainer.
  
  Fig 37: Prying Out Oil Seal Retainer Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the engine rear oil seal retainer.
  
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE ENGINE REAR OIL SEAL
1. Place the oil seal retainer on wooden blocks.
  NOTE: Be careful not to damage the engine rear oil seal retainer.
2. Using a screwdriver and a hammer, tap out the oil seal.
  
  Fig 38: Tapping Out Engine Rear Oil Seal Using Screwdriver & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE WATER PUMP ASSEMBLY
1. Remove the 16 bolts, water pump and gasket.
  
  Fig 39: Identifying Water Pump Assembly & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
1. Remove the 15 bolts and 2 nuts.
  
  Fig 40: Identifying Timing Chain Cover Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.
  
  Fig 41: Prying Between Timing Chain Cover & Cylinder Head Or Cylinder Block With Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.
  
  HINT:
  
  Tape the screwdriver tip before use.
3. Remove the 4 bolts, chain cover plate and gasket.
4. Remove the gasket.
  
  Fig 42: Identifying Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TIMING CHAIN CASE OIL SEAL
1. Using a screwdriver, pry out the oil seal.
  
  Fig 43: Prying Out Oil Seal Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Tape the screwdriver tip before use.
SET NO. 1 CYLINDER TO TDC / COMPRESSION
CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE, 2GR-FSE, 3GR-FSE, 4GR-FSE VALVE TIMING PROCEDURE .
1. Temporarily tighten the pulley set bolt.
2. Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC / compression).
  
  Fig 44: Identifying Timing Mark On Crank Angle Sensor Plate To RH Block Bore Center Line
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check that the timing marks of the camshaft timing gears are aligned with those of the bearing cap.
  
  Fig 45: Aligning Camshaft Timing Gears Timing Marks With Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.
REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
  
  Fig 46: Identifying Stopper Plate, Plunger And Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Move the stopper plate downward to set the lock, and insert a pin of ø 1.27 mm (0.05 in.) into the stopper plate's hole.
3. Remove the 2 bolts and chain tensioner.
  
  Fig 47: Identifying Chain Tensioner Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CHAIN TENSIONER SLIPPER
1. Remove the chain tensioner slipper.
REMOVE CHAIN SUB-ASSEMBLY
1. Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket.
  
  Fig 48: Turning Crankshaft Counterclockwise 10°
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the pulley set bolt.
3. Remove the chain from the crankshaft timing sprocket and place it on the crankshaft.
  
  Fig 49: Identifying Chain Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Turn the camshaft timing gear assembly on the RH bank clockwise (approximately 60°) and set it. Be sure to loosen the chain between the banks.
  
  Fig 50: Identifying Camshaft Timing Gear Setting Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the chain.
REMOVE IDLE SPROCKET ASSEMBLY
1. Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, sprocket and No. 1 idle gear shaft.
  
  Fig 51: Locating Idle Sprocket Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN VIBRATION DAMPER
1. Remove the 2 bolts and vibration damper.
  
  Fig 52: Identifying No. 1 Chain Vibration Damper Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CHAIN VIBRATION DAMPER
1. Remove the 2 vibration dampers.
REMOVE CRANKSHAFT TIMING SPROCKET
1. Remove the crankshaft timing sprocket from the crankshaft.
2. Remove the 2 pulley set keys from the crankshaft.
  
  Fig 53: Identifying Crankshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)
1. While raising the No. 2 chain tensioner, insert a pin of ø 1.0 mm (0.039 in.) into the hole to fix the No. 2 chain tensioner.
  
  Fig 54: Inserting Pin Into Hole To Fix No. 2 Chain Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.
  
  Fig 55: Removing Camshaft Timing Gear Assemblies
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful not to damage the cylinder head with the wrench.
  - Do not disassemble the camshaft timing gear assemblies.
3. Remove the No. 2 chain.
REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
1. Remove the bolt and No. 2 chain tensioner.
  
  Fig 56: Identifying No. 2 Chain Tensioner Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT BEARING CAP (for Bank 1)
1. Check that the camshafts are positioned.
  
  Fig 57: Checking Camshafts Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen and remove the 8 bearing cap bolts.
  
  Fig 58: Identifying Bearing Cap Bolts Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Uniformly loosen and remove the 12 bearing cap bolts.
  
  Fig 59: Removing Bearing Cap Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Uniformly loosen the bolts while keeping the camshaft level.
4. Remove the 5 bearing caps.
REMOVE CAMSHAFT
1. Remove the camshaft.
REMOVE NO. 2 CAMSHAFT
1. Remove the No. 2 camshaft.
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH
1. Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver.
  
  Fig 60: Prying Between Cylinder Head And Camshaft Housing Sub-Assembly RH With Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.
  
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)
1. While pushing down the No. 3 chain tensioner, insert a pin of ø 1.0 mm (0.039 in.) into the hole to fix the No. 3 chain tensioner.
  
  Fig 61: Inserting Pin Into Hole For Fixing No 3 Chain Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.
  
  Fig 62: Removing Camshaft Timing Gear Assemblies Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful not to damage the cylinder head with the wrench.
  - Do not disassemble the camshaft timing gear assemblies.
3. Remove the No. 2 chain.
REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
1. Remove the bolt and No. 3 chain tensioner.
  
  Fig 63: Identifying No. 3 Chain Tensioner Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT BEARING CAP (for Bank 2)
1. Check that the camshafts are positioned.
  
  Fig 64: Checking Camshafts Are Positioned
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen and remove the 8 bearing cap bolts.
  
  Fig 65: Identifying Bearing Cap Bolts Loosening Sequence (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Uniformly loosen and remove the 13 bearing cap bolts.
  
  Fig 66: Identifying Bearing Cap Bolts Loosening Sequence (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Uniformly loosen the bolts while keeping the camshaft level.
4. Remove the 5 bearing caps.
REMOVE NO. 3 CAMSHAFT
1. Remove the No. 3 camshaft.
REMOVE NO. 4 CAMSHAFT
1. Remove the No. 4 camshaft.
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH
1. Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.
  
  Fig 67: Prying Between Cylinder Head & Camshaft Housing With Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.
  
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Remove the 24 valve rocker arms.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE VALVE LASH ADJUSTER ASSEMBLY
1. Remove the 24 valve lash adjusters from the cylinder head.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE CYLINDER HEAD SUB-ASSEMBLY RH
1. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts. Remove the 8 cylinder head bolts and plate washers.
  
  Fig 68: Removing Cylinder Head Bolts And Plate Washers In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful not to drop washers into the cylinder head.
  - Cylinder head warpage or cracking could result from removing bolts in an incorrect order.
  HINT:
  
  Be sure to keep separate the removed parts for each installation position.
2. Remove the cylinder head and gasket.
REMOVE CYLINDER HEAD SUB-ASSEMBLY LH
1. Uniformly loosen and remove the bolts.
  
  Fig 69: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts. Remove the 8 cylinder head bolts and plate washers.
  
  Fig 70: Removing Cylinder Head Bolts And Plate Washers In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful not to drop washers into the cylinder head.
  - Cylinder head warpage or cracking could result from removing bolts in an incorrect order.
  HINT:
  
  Be sure to keep separate the removed parts for each installation position.
3. Remove the cylinder head and gasket.
REMOVE WATER INLET PIPE
1. Separate the No. 1 water by-pass hose.
2. Remove the 2 bolts and water inlet pipe.
  
  Fig 71: Identifying Water Inlet Pipe Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE STEM CAP
1. Remove the valve stem caps from the cylinder heads.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE INTAKE VALVE
1. Using SST, compress the compression spring and remove the valve spring retainer locks.
  SST 09202-70020 (09202-00010)
  
  Fig 72: Removing Valve Spring Retainer Locks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the retainer, compression spring and valve.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE EXHAUST VALVE
1. Using SST, compress the compression spring and remove the valve spring retainer locks.
  SST 09202-70020(09202-00010)
  
  Fig 73: Removing Valve Spring Retainer Locks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the retainer, compression spring and valve.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE VALVE STEM OIL SEAL
1. Using needle-nose pliers, remove the oil seals.
  
  Fig 74: Removing Valve Stem Oil Seals Using Needle-Nose Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE SPRING SEAT
1. Using compressed air and a magnetic finger, remove the valve spring seats by blowing air onto them.
  
  Fig 75: Using Compressed Air & Magnetic Finger To Remove Valve Spring Seats
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 STRAIGHT SCREW PLUG
1. Using a 10 mm hexagon wrench, remove the 4 screw plugs and 4 gaskets.
  
  Fig 76: Using Hexagon Wrench To Remove No. 1 Straight Screw Plugs & Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: If water leaks from the straight screw plug or the plug corrodes, replace it.
REMOVE NO. 2 STRAIGHT SCREW PLUG
1. Using a 14 mm hexagon wrench, remove the screw plugs and gaskets.
  
  Fig 77: Using Hexagon Wrench To Remove No. 2 Straight Screw Plugs & Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: If water leaks from the straight screw plug or the plug corrodes, replace it.
REMOVE RING PIN
NOTE: It is not necessary to remove the ring pin unless it is being replaced.
REMOVE STUD BOLT
NOTE: If the stud bolt is deformed or the threads are damaged, replace it.
REMOVE INTAKE VALVE GUIDE BUSH
1. Heat the cylinder head to 80 to 100°C (176 to 212°F).
2. Place the cylinder head on wooden blocks.
3. Using SST and a hammer, tap out the guide bushes.
  SST 09201 -10000 (09201-01050), 09950-70010 (09951-07100)
  
  Fig 78: Using SST & Hammer To Tap Out Intake Valve Guide Bushes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST VALVE GUIDE BUSH
1. Heat the cylinder head to 80 to 100°C (176 to 212°F).
2. Place the cylinder head on wooden blocks.
3. Using SST and a hammer, tap out the guide bushes.
  SST 09201 -10000 (09201-01050), 09950-70010 (09951-07100)
  
  Fig 79: Using SST & Hammer To Tap Out Exhaust Valve Guide Bushes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD
1. Check that the matchmarks on the connecting rod and cap are aligned.
  HINT:
  
  The matchmarks on the connecting rods and caps are for ensuring the correct reassembly.
2. Remove the 2 connecting rod cap bolts.
  
  Fig 80: Removing Connecting Rod Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
  
  Fig 81: Removing Connecting Rod Cap & Lower Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Keep the lower bearing inserted to the connecting rod cap.
4. Using a ridge reamer, remove all the carbon from the top of the cylinder.
  
  Fig 82: Removing Carbon From Top Of Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
  HINT:
  - Keep the bearing, connecting rod and cap together.
  - Arrange the piston and connecting rod assemblies in the correct order.
REMOVE CONNECTING ROD BEARING
HINT:

Arrange the removed parts in the correct order.
REMOVE CRANKSHAFT
1. Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in several steps.
  
  Fig 83: Removing Main Bearing Cap Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen the 16 bearing cap bolts in several steps.
  
  Fig 84: Identifying Bearing Cap Bolts Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and lower bearings.
  
  Fig 85: Removing Main Bearing Caps & Lower Bearings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Push up on the cap little by little, from the right and left side alternately so that the cap can be removed.
  - Be careful not to damage the joint surface of the cylinder block and the main bearing cap.
4. Remove the crankshaft.
REMOVE CRANKSHAFT BEARING
HINT:

Arrange the removed parts in the correct order.
REMOVE CRANKSHAFT THRUST WASHER SET
1. Remove the upper bearings and upper thrust washers from the cylinder block.
  
  Fig 86: Identifying Upper Thrust Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON RING SET
1. Using a piston ring expander, remove the 2 compression rings.
  
  Fig 87: Removing Compression Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the oil ring expander and 2 side rails by hand.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE PISTON SUB-ASSEMBLY WITH PIN
1. Check the fitting condition between the piston and piston pin.
  
  Fig 88: Checking Fitting Condition Between Piston & Piston Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Try to move the piston back and forth on the piston pin.
    If any movement is felt, replace the piston and pin as a set.
2. Disconnect the connecting rod from the piston.
  1. Using a screwdriver, pry off the snap rings from the piston.
    
    Fig 89: Prying Off Snap Rings From Piston Using Screwdriver
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Gradually heat the piston to approximately 80°C (176°F).
    
    Fig 90: Heating Piston
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Using a brass bar and plastic hammer, lightly tap out the piston pin and remove the connecting rod.
    
    Fig 91: Removing Connecting Rod
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    HINT:
    - The piston and pin are a matched set.
    - Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
3. Using a gasket scraper, remove the carbon from the piston top.
  
  Fig 92: Using Gasket Scraper To Remove Carbon From Piston Top
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
  
  Fig 93: Cleaning Piston Ring Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using solvent and a brush, thoroughly clean the piston.
  
  Fig 94: Cleaning Piston Using Solvent & Brush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not use a wire brush.
REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm hexagon wrench, remove the bolts and oil nozzles.
2. Check the 3 oil nozzles for damage or clogging.
  If necessary, replace the oil nozzle.
CLEAN CYLINDER BLOCK