Engine Unit: Disassembly: Disassembly

REMOVE OIL FILLER CAP SUB-ASSEMBLY
1. Remove the oil filler cap sub-assembly and oil filler gasket.
REMOVE SPARK PLUG
1. Remove the 6 spark plugs.
REMOVE OIL PAN DRAIN PLUG
1. Remove the oil pan drain plug and oil pan drain plug gasket.
  
  Fig 1: Identifying Oil Pan Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VENTILATION VALVE SUB-ASSEMBLY
1. Remove the ventilation valve sub-assembly.
  
  Fig 2: Identifying Ventilation Valve Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT POSITION SENSOR
1. Remove the 4 bolts and 4 camshaft position 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 camshaft oil control valves.
  
  Fig 4: Identifying Camshaft Timing Oil Control Valves And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT POSITION SENSOR
1. Remove the bolt and crankshaft position sensor.
  
  Fig 5: Identifying Crankshaft Position Sensor And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 OIL PIPE
1. Remove the 2 oil pipe unions and No. 1 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.
  
  Fig 7: Identifying Oil Pipe Union Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 oil pipe unions and oil pipe.
3. Remove the oil control valve filter RH and gaskets.
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Remove the cylinder block water drain cocks from the cylinder block.
  
  Fig 8: Identifying Water Drain Cock Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the cylinder block 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: Identifying Hose, O-Ring And 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.
  
  Fig 11: Identifying Oil Filter Cap & SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09228-06501
6. Remove the oil filter element and O-ring from the oil filter cap sub-assembly.
  
  Fig 12: Identifying Oil Filter Element And 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.
  
  Fig 13: Identifying Crankshaft Pulley Component Bolt & SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09213-70011
    - 09213-70020
  - SST: 09330-00021
2. Using SST, remove the crankshaft pulley bolt and crankshaft pulley.
  
  Fig 14: Identifying Crankshaft Pulley, Bolt And SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-50013
    - 09951-05010
    - 09952-05010
    - 09953-05020
    - 09954-05021
REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH
1. Remove the 6 bolts and No. 1 front engine mounting bracket LH.
  
  Fig 15: 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 16: Identifying Water Inlet, Thermostat & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gasket.
3. Remove the 2 stud bolts.
4. Separate the No. 1 water by-pass hose.
5. Remove the 2 bolts, nut, and water inlet housing.
  
  Fig 17: Identifying Water Inlet Housing Bolts & Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the drain cock plug.
7. Remove the drain cock.
8. Remove the 2 O-rings.
  
  Fig 18: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER OUTLET
1. Remove the 2 bolts, 4 nuts, and water outlet.
  
  Fig 19: Identifying Bolts, Nuts And Water Outlet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 gaskets and O-ring.
  
  Fig 20: Identifying Gaskets & O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for RH Side)
1. Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.
  
  Fig 21: Identifying Cylinder Head Cover Sub-Assembly (For RH Side)
  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 LH Side)
1. Remove the 12 bolts, seal washer, cylinder head cover sub-assembly LH and cylinder head cover gasket LH.
  
  Fig 23: Identifying Cylinder Head Cover Sub-Assembly (For LH Side)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
2. Remove the 3 gaskets.
  
  Fig 24: Identifying 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 oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.
  
  Fig 26: Inserting Blade Of Oil Pan Seal Cutter Between Oil Pans
  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 sub-assembly, and gasket.
  
  Fig 27: Identifying Oil Strainer Bolt & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a "TORX" socket wrench E6, remove the 2 stud bolts.
REMOVE OIL PAN SUB-ASSEMBLY
1. Remove the 16 bolts and 2 nuts.
  
  Fig 28: Identifying Oil Pan Sub-Assembly, Bolts And 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 29: Identifying Oil Pan And 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 30: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a "TORX" socket wrench E8, remove the 2 stud bolts.
REMOVE NO. 1 OIL PAN BAFFLE PLATE
1. Remove the 7 bolts and No. 1 oil pan baffle plate.
  
  Fig 31: Identifying Oil Pan Baffle Plate Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE REAR OIL SEAL RETAINER
1. Remove the 6 bolts.
  
  Fig 32: Identifying Engine Rear Oil Seal Retainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, pry out the engine rear oil seal retainer.
  
  Fig 33: Identifying Oil Seal Retainer Component
  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 engine rear oil seal retainer on wooden blocks.
  
  Fig 34: Identifying Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the engine rear oil seal retainer.
2. Using a screwdriver and a hammer, tap out the engine rear oil seal.
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE WATER PUMP ASSEMBLY
1. Remove the 16 bolts, water pump assembly, and gasket.
  
  Fig 35: Identifying 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.
  
  Fig 36: Identifying Timing Chain Cover Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the timing chain cover sub-assembly by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.
  
  Fig 37: Identifying Bolts, Chain Cover Plate & Gasket
  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 38: Identifying Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TIMING CHAIN CASE OIL SEAL
1. Using a screwdriver, pry out the timing chain case oil seal.
  
  Fig 39: Identifying Timing Chain Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Tape the screwdriver tip before use.
SET NO. 1 CYLINDER TO TDC/COMPRESSION
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
  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.
  
  Fig 41: Identifying Bearing Cap Timing Marks
  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 42: Identifying No. 1 Chain Tensioner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm (0.05 in.) into the stopper plate's hole.
3. Remove the 2 bolts and No. 1 chain tensioner assembly.
  
  Fig 43: Identifying No. 1 Chain Tensioner Assembly & 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 sub-assembly of the crankshaft timing sprocket.
  
  Fig 44: Identifying Timing Mark On Crankshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the pulley set bolt.
3. Remove the chain sub-assembly 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. Be sure to loosen the chain between the banks.
  
  Fig 46: Camshaft Timing Gear Setting Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the chain sub-assembly.
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: Identifying 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 No. 1 chain vibration damper.
  
  Fig 48: Identifying No. 1 Chain Vibration Damper Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CHAIN VIBRATION DAMPER
1. Remove the 2 No. 2 chain vibration dampers.
REMOVE CRANKSHAFT TIMING SPROCKET
1. Remove the crankshaft timing sprocket from the crankshaft.
  
  Fig 49: Identifying Crankshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 pulley set keys from the crankshaft.
REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for RH Side)
1. While raising the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix the No. 2 chain tensioner.
  
  Fig 50: Inserting Pin Of 1.0 mm Into Hole To Fix No. 2 Chain Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.
  
  Fig 51: Identifying Flange Bolts Of Camshaft Timing Gear Assembly And SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09922-10010
  NOTE: Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly LH with a new one.
3. Remove the 2 flange bolts, the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH together with the No. 2 chain.
REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
1. Remove the bolt and No. 2 chain tensioner assembly.
  
  Fig 52: Identifying No. 2 Chain Tensioner Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT BEARING CAP (for RH Side)
1. Check that the camshafts are positioned as shown in the illustration.
  
  Fig 53: 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.
  
  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.
  
  Fig 55: Identifying Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Uniformly loosen the bolts while keeping the camshafts 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 56: Prying Between Cylinder Head And Camshaft Housing Sub-Assembly
  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 LH Side)
1. While pushing down the No. 3 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix the No. 3 chain tensioner assembly.
  
  Fig 57: Inserting Pin Into Hole For Fixing No 3 Chain Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.
  
  Fig 58: Identifying SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09922-10010
  NOTE: Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly LH with a new one.
3. Remove the 2 flange bolts, the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH together with the No. 2 chain.
REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
1. Remove the bolt and No. 3 chain tensioner assembly.
  
  Fig 59: Identifying No. 3 Chain Tensioner Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT BEARING CAP (for LH Side)
1. Check that the camshafts are positioned as shown.
  
  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.
  
  Fig 61: 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 in the sequence shown.
  
  Fig 62: Identifying Bearing Cap Bolts Loosening Sequence (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Uniformly loosen the bolts while keeping the camshafts 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 sub-assembly LH by prying between the cylinder head and camshaft housing sub-assembly LH with a screwdriver.
  
  Fig 63: Identifying Camshaft Housing Sub-Assembly
  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 No. 1 valve rocker arm subassemblies.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE VALVE LASH ADJUSTER ASSEMBLY
1. Remove the 24 valve lash adjuster assemblies 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. Remove the 8 cylinder head bolts and plate washers.
  
  Fig 64: Identifying Cylinder Head Sub-Assembly Bolts Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 sub-assembly RH and cylinder head gasket.
REMOVE CYLINDER HEAD SUB-ASSEMBLY LH
1. Uniformly loosen and remove the bolts in the sequence shown.
  
  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. Remove the 8 cylinder head bolts and plate washers.
  
  Fig 66: Identifying Cylinder Head Bolts Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 sub-assembly LH and No. 2 cylinder head gasket.
REMOVE WATER INLET PIPE
1. Separate the No. 1 water by-pass hose.
2. Remove the 2 bolts and water inlet pipe.
  
  Fig 67: Identifying Water Inlet Pipe
  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 and wooden blocks, compress the inner compression spring and remove the valve spring retainer locks.
  
  Fig 68: Identifying SST Inner Compression Spring & Valve Spring Retainer Locks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09202-70020
    - 09202-00010
2. Remove the valve spring retainer, inner compression spring and intake valve.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE EXHAUST VALVE
1. Using SST, compress the inner compression spring and remove the valve spring retainer locks.
  
  Fig 69: Identifying SST Exhaust Valve Inner Compression Spring & Valve Spring Retainer Locks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09202-70020
    - 09202-00010
2. Remove the valve spring retainer, inner compression spring and exhaust valve.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE VALVE STEM OIL SEAL
1. Using needle-nose pliers, remove the valve stem oil seals.
  
  Fig 70: Identifying Valve Stem Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE SPRING SEAT
1. Using compressed air and a magnet hand, remove the valve spring seats by blowing air onto them.
  
  Fig 71: Identifying 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 No. 1 straight screw plugs and 4 gaskets.
  
  Fig 72: Identifying No. 1 Straight Screw Plug
  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 2 No. 2 straight screw plugs and 2 gaskets.
  
  Fig 73: Identifying Straight Screw Plugs
  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.
  
  Fig 74: Identifying Intake Valve Guide Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09201-10000
    - 09201-01050
  - SST: 09950-70010
    - 09951-07100
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.
  
  Fig 75: Identifying Exhaust Valve Guide Bush And SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09201-10000
    - 09201-01050
  - SST: 09950-70010
    - 09951-07100
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: Identifying Connecting Rod Cap And 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 77: Identifying 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 78: Identifying 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 and in the sequence shown.
  
  Fig 79: Identifying Main Bearing Cap Bolts Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen the 16 bearing cap bolts in several steps and in the sequence shown.
  
  Fig 80: 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 81: Prying Out Main Bearing Caps
  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 surfaces of the cylinder block and the main bearing cap.
4. Remove the crankshaft.
REMOVE CRANKSHAFT BEARING
1. Remove the upper crankshaft bearing and lower crankshaft bearing.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE CRANKSHAFT THRUST WASHER SET
1. Remove the upper crankshaft bearings and upper crankshaft thrust washers from the cylinder block sub-assembly.
  
  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.
  
  Fig 83: Identifying 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 84: Identifying Fitting Condition Between Piston And Piston Pin Components
  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.
  
  Fig 85: Identifying Snap Rings From Piston Component
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using a screwdriver, pry off the snap rings from the piston.
  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.
    
    Fig 87: Identifying 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 88: Identifying Carbon From Piston Top Component
  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 Using A Groove Cleaning Tool
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using solvent and a brush, thoroughly clean the piston.
  
  Fig 90: Cleaning Piston Using Solvent And 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 No. 1 oil nozzle sub-assembly.
  
  Fig 91: Identifying Bolt And Oil Nozzle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the 3 oil nozzles for damage or clogging.
  If necessary, replace the No. 1 oil nozzle subassembly.
CLEAN CYLINDER BLOCK