Engine Unit: Disassembly

WARNING: This page is about a different car, the 2007 Lexus ES 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 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: Locating 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 Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT POSITION SENSOR
1. Remove the 4 bolts and 4 sensors.
  
  Fig 3: Locating Camshaft Position Sensors With 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: Locating Camshaft Timing Oil Control Valves With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT POSITION SENSOR
1. Remove the bolt and sensor.
  
  Fig 5: Locating Crankshaft Position Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 OIL PIPE
1. Remove the 2 oil pipe unions and oil pipe.
2. Remove the oil control valve filter LH and gaskets.
  
  Fig 6: Locating Oil Pipe Unions And Oil Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PIPE
1. Remove the bolt.
2. Remove the 2 oil pipe unions and oil pipe.
3. Remove the oil control valve filter RH and gaskets.
  
  Fig 7: Locating Oil Pipe Unions And Oil Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Remove the water drain cocks from the cylinder block.
2. Remove the water drain cock plugs from the water drain cocks.
  
  Fig 8: Locating Water drain Cock Plugs From Water drain Cocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL FILTER ELEMENT
1. Remove the drain plug.
  NOTE: Do not remove the O-ring from the oil filter cap.
  
  Fig 9: Locating Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the hose to the pipe.
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.
  
  Fig 10: Connecting Hose To Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, remove the oil filter cap.
  SST 09228-06501
  
  Fig 11: Removing Oil Filter Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the oil filter element and O-ring from the oil filter cap.
  NOTE: Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.
  
  Fig 12: Applying Light Coat Of Engine Oil To O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT PULLEY
1. Using SST, loosen the crankshaft pulley bolt.
  SST 09213-70011 (09213-70020), 09330-00021
  
  Fig 13: Loosening 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: Removing Crankshaft Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT ENGINE MOUNTING BRACKET NO. 1 LH
1. Remove the 6 bolts and engine mounting bracket.
2. Using a "TORX" socket wrench E8, remove the 2 stud bolts.
  
  Fig 15: Locating Engine Mounting Bracket Front And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER INLET HOUSING
1. Remove the 2 nuts, water inlet, and thermostat.
2. Remove the gasket.
3. Remove the 2 stud bolts.
4. Separate the No. 1 water by-pass hose.
  
  Fig 16: Locating Water Inlet With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 2 bolts, nut, and water inlet housing.
6. Remove the drain cock plug.
7. Remove the drain cock.
  
  Fig 17: Locating Bolts, Nut, And Water Inlet Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the 2 O-rings.
  
  Fig 18: Locating O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER OUTLET
1. Remove the 2 bolts, 4 nuts, and water outlet.
  
  Fig 19: Locating Bolts, Nuts And Water Outlet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 gaskets and O-ring.
  
  Fig 20: Locating Gaskets And 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 21: Locating Bolts, Head Cover And Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 gaskets.
  
  Fig 22: Identifying Gaskets
  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.
  NOTE: The baffle plate is located on the back of the portion shown in the illustration. do not damage the baffle plate when removing the head cover.
  
  Fig 23: Locating Bolts, Seal Washer, Head Cover And Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 gaskets.
  
  Fig 24: Locating Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
1. Remove the 16 bolts and 2 nuts.
  
  Fig 25: Identifying Oil Pan With Bolts And 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
  
  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.
  
  Fig 26: Inserting Blade Of SST Between Oil Pans
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 27: Locating Oil Strainer With Bolt And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PAN SUB-ASSEMBLY
1. Remove the 16 bolts and 2 nuts.
  HINT:
  
  Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.
  
  Fig 28: Locating Oil Pan Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.
  NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.
  
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 29: Locating Between Oil Pan And Cylinder Block With Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 O-rings.
4. Using a "TORX" socket wrench E8, remove the 2 stud bolts.
  
  Fig 30: Locating O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PAN BAFFLE PLATE
1. Remove the 7 bolts and baffle plate.
  
  Fig 31: Locating Oil Pan Baffle Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE REAR OIL SEAL RETAINER
1. Remove the 6 bolts.
  
  Fig 32: Locating Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, pry out the oil seal retainer.
  NOTE: Be careful not to damage the engine rear oil seal retainer.
  
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 33: Prying Out Oil Seal Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 34: Tapping Out Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER PUMP ASSEMBLY
1. Remove the 16 bolts, water pump, and gasket.
  
  Fig 35: Locating Bolts, Water Pump And Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
1. Remove the 15 bolts and 2 nuts as shown in the illustration.
  
  Fig 36: Locating Timing Chain Cover Bolts And 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.
  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.
  
  Fig 37: Prying Between Timing Chain Cover And Cylinder Head Or Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the gasket.
  
  Fig 38: Locating Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TIMING CHAIN CASE OIL SEAL
1. Using a screwdriver, pry out the oil seal.
  HINT:
  
  Tape the screwdriver tip before use.
Fig 39: Prying Out Oil Seal Using Screwdriver
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 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 40: 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 as shown in the illustration.
  If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.
  
  Fig 41: Identifying Bearing Cap Timing Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
2. Move the stopper plate downward to set the lock, and insert a pin of ø1.27 mm (0.05 in.) into the stopper plate's hole.
  
  Fig 42: Locating No.1 Chain Tensioner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 bolts and chain tensioner.
  
  Fig 43: Locating Chain Tensioner With 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.
2. Remove the pulley set bolt.
  
  Fig 44: Identifying Timing Mark On Crankshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the chain from the crankshaft timing sprocket and place it on the crankshaft.
  
  Fig 45: 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 as shown in the illustration. Be sure to loosen the chain between the banks.
5. Remove the chain.
  
  Fig 46: Camshaft Timing Gear Setting Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 47: Removing No. 2 Idle Gear Shaft, Sprocket, And No. 1 Idle Gear Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN VIBRATION DAMPER
1. Remove the 2 bolts and vibration damper.
Fig 48: Locating Chain Vibration Damper With 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 49: Locating Pulley Set Keys From Crankshaft
  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 50: Inserting Pin Into Hole For Fixing 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.
  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.
  
  Fig 51: Removing Camshaft Timing Gear Assemblies
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
1. Remove the bolt and No. 2 chain tensioner.
  
  Fig 52: 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 as shown in the illustration.
  
  Fig 53: Identifying Camshaft Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
  
  Fig 54: Identifying Bearing Cap Bolts Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Uniformly loosen and remove the 12 bearing cap bolts in the sequence shown in the illustration.
  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.
  NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.
  
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 56: Prying Between Cylinder Head And Camshaft Housing Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 57: 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.
  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.
  
  Fig 58: Removing Bolts And Camshaft Timing Gear Assemblies
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
1. Remove the bolt and No. 3 chain tensioner.
  
  Fig 59: 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 as shown in the illustration.
  
  Fig 60: Identifying Knock Pin Of Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
  
  Fig 61: Identifying Bearing Cap Bolts Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Uniformly loosen and remove the 13 bearing cap bolts in the sequence shown in the illustration.
  NOTE: Uniformly loosen the bolts while keeping the camshaft level.
4. Remove the 5 bearing caps.
  
  Fig 62: Locating Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.
  
  HINT:
  
  Tape the screwdriver tip before use.
Fig 63: Prying Between Cylinder Head And Camshaft Housing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
  NOTE:
  - Be careful not to drop the washers into the cylinder head.
  - Cylinder head warpage or cracking could result from removing the 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.
  
  Fig 64: Locating Cylinder Head Bolts And Plate Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD SUB-ASSEMBLY LH
1. Uniformly loosen and remove the bolts in the sequence shown in the illustration.
  
  Fig 65: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
  NOTE:
  - Be careful not to drop the washers into the cylinder head.
  - Cylinder head warpage or cracking could result from removing the 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.
  
  Fig 66: Locating Cylinder Head Bolts And Plate Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER INLET PIPE
1. Separate the No. 1 water by-pass hose.
2. Remove the 2 bolts and water inlet pipe.
  
  Fig 67: Locating Water Bypass Hose
  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)
2. Remove the retainer, compression spring, and valve.
  HINT:
  
  Arrange the removed parts in the correct order.
  
  Fig 68: Compressing Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST VALVE
1. Using SST, compress the compression spring and remove the valve spring retainer locks.
  SST 09202-70020(09202-00010)
2. Remove the retainer, compression spring, and valve.
  HINT:
  
  Arrange the removed parts in the correct order.
  
  Fig 69: Compressing Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE STEM OIL SEAL
1. Using needle-nose pliers, remove the oil seals.
  
  Fig 70: Removing Valve Stem Oil Seal
  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 71: Removing Valve Spring Seat
  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.
  NOTE: If water leaks from the straight screw plug or the plug corrodes, replace it.
  
  Fig 72: Identifying Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 STRAIGHT SCREW PLUG
1. Using a 14 mm hexagon wrench, remove the screw plugs and gaskets.
  NOTE: If water leaks from the straight screw plug or the plug corrodes, replace it.
Fig 73: Locating Straight Screw Plugs
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 74: Tapping Intake Valve Guide Bush
  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 75: Tapping Exhaust Valve Guide Bush
  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 76: 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.
  HINT:
  
  Keep the lower bearing inserted to the connecting rod cap.
  
  Fig 77: Removing Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a ridge reamer, remove all the carbon from the top of the cylinder.
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.
  Fig 78: Identifying Carbon From Top Of Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 and in the sequence shown in the illustration.
  
  Fig 79: Removing Connecting Rod Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen the 16 bearing cap bolts in several steps and in the sequence shown in the illustration.
  
  Fig 80: Identifying Bearing Cap Bolts
  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.
  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.
  Fig 81: Prying Out Main Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 82: Identifying Upper Bearings And Upper Thrust Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON RING SET
1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the oil ring expander and 2 side rails by hand.
  HINT:
  
  Arrange the removed parts in the correct order.
  
  Fig 83: Identifying Compression Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON SUB-ASSEMBLY WITH PIN
1. Check the fitting condition between the piston and piston pin.
  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.
    
    Fig 84: Locating Fitting Condition Between Piston And Piston Pin
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the connecting rod from the piston.
  1. Using a screwdriver, pry off the snap rings from the piston.
    
    Fig 85: Prying Off Snap Rings From Piston
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Gradually heat the piston to approximately 80°C(176°F).
    
    Fig 86: 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.
    HINT:
    - The piston and pin are a matched set.
    - Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
      
      Fig 87: Removing Connecting Rod
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a gasket scraper, remove the carbon from the piston top.
  
  Fig 88: Removing 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 89: Cleaning Piston Ring Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using solvent and a brush, thoroughly clean the piston.
  NOTE: do not use a wire brush.
  
  Fig 90: Cleaning Piston Using Solvent And Brush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
Fig 91: Identifying Bolt And Oil Nozzle
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CLEAN CYLINDER BLOCK