Engine Unit: Disassembly

WARNING: This page is about a different car, the 2008 Toyota Avalon. 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 sub-assembly.
REMOVE SPARK PLUG
REMOVE OIL PAN DRAIN PLUG
1. Remove the drain plug and gasket.
  
  Fig 1: Locating Drain Plug And Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VENTILATION VALVE SUB-ASSEMBLY
1. Remove the ventilation valve sub-assembly.
  
  Fig 2: Locating 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: Locating Camshaft Position Sensors Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Remove the 4 bolts and 4 camshaft timing oil control valves.
  
  Fig 4: Locating Camshaft Timing Oil Control Valves Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANK POSITION SENSOR
1. Remove the bolt and crankshaft position sensor.
  
  Fig 5: Locating Crankshaft Position Sensor Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PIPE NO. 1
1. Remove the 2 oil pipe unions and oil pipe No. 1.
2. Remove the oil control valve filter LH and gaskets.
  
  Fig 6: Locating Oil Pipe Unions And Oil Pipe No. 1
  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 Bolts
  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.
  
  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: Identifying Oil Filter Element And 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 Bolt And Crankshaft Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE MOUNTING BRACKET FRONT NO. 1 LH
1. Remove the 6 bolts, and engine mounting bracket front No. 1 LH.
  
  Fig 15: Locating Engine Mounting Bracket Front No. 1 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 drain cock plug.
4. Remove the drain cock.
  
  Fig 16: Locating Water Inlet Housing Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 2 bolts, nut, and water inlet housing.
  
  Fig 17: Locating Water Inlet Housing Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. 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 Water Outlet Bolts And Nuts
  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 LH
1. Remove the 12 bolts, head cover and gasket.
  
  Fig 21: Locating Head Cover And Gasket And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
1. Remove the 12 bolts, head cover and gasket.
  
  Fig 22: Locating Head Cover And Gasket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PAN SUB-ASSEMBLY NO. 2
1. Remove the 16 bolts and 2 nuts.
  
  Fig 23: Locating Oil Pan Sub-Assembly No. 2 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 oil pan sub-assembly No. 2.
  SST 09032-00100
  
  NOTE: Be careful not to damage the contact surfaces of the oil pans.
  
  Fig 24: 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.
  
  Fig 25: Locating Oil Strainer Sub-Assembly Bolts 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 26: Locating Oil Pan Sub-Assembly Bolts And Nuts
  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 27: Identifying Protective Tape Applying Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 O-rings.
  
  Fig 28: Locating O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PAN BAFFLE PLATE NO.1
1. Remove the 7 bolts and oil pan baffle plate.
  
  Fig 29: Locating Oil Pan Baffle Plate Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE REAR OIL SEAL
1. Remove the 6 bolts.
  
  Fig 30: Locating Engine Rear Oil Seal Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, pry out the oil seal retainer.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 31: Prying Out Oil Seal Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER PUMP ASSEMBLY
1. Remove the 16 bolts, water pump and gasket.
  
  Fig 32: Locating Water Pump And Gasket Bolts
  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 33: Locating Timing Chain Cover Sub-Assembly 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 34: Locating Chain Cover Plate And Gasket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the gasket.
  
  Fig 35: Identifying Gasket
  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 36: 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 the timing marks 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 37: Identifying Timing Marks Of Camshaft Timing Gears
  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 hexagon wrench into the stopper plate's hole.
3. Remove the 2 bolts and chain tensioner.
REMOVE CHAIN TENSIONER SLIPPER
1. Remove the chain tensioner slipper.
  
  Fig 38: Identifying Chain Tensioner Slipper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CHAIN SUB-ASSEMBLY
1. Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing gear.
2. Remove the chain from the crank timing gear and place it on the crankshaft.
  
  Fig 39: Identifying Chain Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. 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 center banks.
4. Remove the chain.
  
  Fig 40: Identifying Chain Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE IDLE SPROCKET ASSEMBLY
1. Using a 10 mm hexagon wrench, remove the idle gear shaft No. 2, idle sprocket and idle gear shaft No. 1.
  
  Fig 41: Locating Idle Sprocket Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN VIBRATION DAMPER
1. Remove the 2 bolts and chain vibration damper No. 1.
REMOVE NO. 2 CHAIN VIBRATION DAMPER
1. Remove the 2 chain vibration dampers.
  
  Fig 42: Locating Chain Vibration Dampers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT TIMING GEAR
1. Remove the pulley set bolt.
2. Remove the crankshaft timing gear from the crankshaft.
3. Remove the 2 pulley set keys from the crankshaft.
  
  Fig 43: Identifying Crankshaft Timing Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for RH BANK)
1. While raising up the chain tensioner No. 2, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it.
  
  Fig 44: Inserting Pin Into Hole
  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 gears.
  NOTE:
  - Be careful not to damage the cylinder head with the wrench.
  - Do not disassemble the camshaft timing gear assembly.
3. Remove the No. 2 chain.
  
  Fig 45: Holding Hexagonal Portion Of Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
1. Remove the bolt and chain tensioner No. 2.
  
  Fig 46: Locating Chain Tensioner No. 2 Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT BEARING CAP
1. Remove the 3 gaskets.
  
  Fig 47: Locating Camshaft Bearing Cap Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Make sure that the knock pin of the camshaft is positioned as shown in the illustration.
  
  Fig 48: Identifying Camshaft Positioned
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
  
  Fig 49: Identifying Loosening Sequence Of Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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.
5. Remove the 5 bearing caps.
REMOVE CAMSHAFT
1. Remove the camshaft.
REMOVE NO. 2 CAMSHAFT
1. Remove the No. 2 camshaft.
  
  Fig 50: Identifying Loosening Sequence Of Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 51: Identifying Protective Tape Applying Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for LH BANK)
1. While pushing down the chain tensioner No. 3, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it.
  
  Fig 52: Inserting Pin Into Hole
  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 gears.
  NOTE:
  - Be careful not to damage the cylinder head with the wrench.
  - Do not disassemble the camshaft timing gear assembly.
3. Remove the No. 2 chain.
  
  Fig 53: Holding Hexagonal Portion Of Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
1. Remove the bolt and chain tensioner No. 3.
  
  Fig 54: Locating Chain Tensioner No. 3 Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT BEARING CAP
1. Remove the 3 gaskets.
  
  Fig 55: Locating Camshaft Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Make sure that the knock pin of the camshaft is positioned as shown in the illustration.
  
  Fig 56: Identifying Camshaft Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
  
  Fig 57: Identifying Loosening Sequence Of Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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.
5. Remove the 5 bearing caps.
REMOVE NO. 4 CAMSHAFT
1. Remove the No. 4 camshaft.
REMOVE NO. 3 CAMSHAFT
1. Remove the No. 3 camshaft.
  
  Fig 58: Identifying Loosening Sequence Of Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  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.
  
  Fig 59: Identifying Protective Tape Applying Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD LH
1. Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.
  
  Fig 60: Identifying Loosening Sequence Of 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 washers into the cylinder head.
  - Head warpage or cracking could result from not removing bolts in an incorrect order.
  HINT:
  
  Be sure to keep the removed parts separate for each installation position.
  
  Fig 61: Identifying Loosening Sequence Of Cylinder Head Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the cylinder head and gasket.
REMOVE CYLINDER HEAD SUB-ASSEMBLY
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 washers into the cylinder head.
  - Head warpage or cracking could result from not removing bolts in an incorrect order.
  HINT:
  
  Be sure to keep the removed parts separate for each installation position.
  
  Fig 62: Identifying Cylinder Head Sub-Assembly Bolts Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the cylinder head and gasket.
REMOVE WATER INLET PIPE
1. Separate the knock sensor wire.
2. Remove the 2 bolts and water outlet pipe.
3. Separate the water by-pass hose No. 1.
REMOVE VALVE STEM CAP
1. Remove the valve stem caps from the cylinder head.
  HINT:
  
  Arrange the removed parts in the correct order.
  
  Fig 63: Locating Water Outlet Pipe Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INTAKE VALVE
1. Using SST and wooden blocks, compress the compression spring and remove the valve 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 64: Compressing Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST VALVE
1. Using SST and wooden blocks, compress the compression spring and remove the valve 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 65: Compressing Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE STEM OIL SEAL
1. Using needle-nose pliers, remove the oil seals.
  
  Fig 66: Removing Oil Seals
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE SPRING SEAT
1. Using compressed air and a magnetic finger, remove the valve spring seat by blowing air onto it.
  
  Fig 67: Removing Valve Spring Seat By Blowing Air
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WITH HEAD STRAIGHT SCREW PLUG NO. 1
1. Using a 10 mm hexagon wrench, remove the 4 screw plugs and 4 gaskets.
  NOTE: If water leaks from the w/ head straight screw plug No. 1 or the plug is corroded, replace it.
  
  Fig 68: Removing Screw Plugs And Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WITH HEAD STRAIGHT SCREW PLUG NO. 2
1. Using a 14 mm hexagon wrench, remove the 2 screw plugs and 2 gaskets.
  NOTE: If water leaks from the w/ head straight screw plug No. 2 or the plug is corroded, 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.

Fig 69: Locating Screw Plugs
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. 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 70: Removing 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 the several steps and in the sequence shown in the illustration.
  
  Fig 71: Identifying Crankshaft Main Bearing Cap Bolts Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen the 16 bearing cap bolts in several steps in the sequence shown in the illustration.
  
  Fig 72: Identifying Bearing Cap Bolts Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, pry out main bearing caps. Remove the 4 main bearing caps and lower bearings.
  NOTE:
  - Pull up the main cap little by little to the right and the left in turns.
  - Be careful not to damage the joint surface of the cylinder block and the main bearing caps.
REMOVE CRANKSHAFT BEARING
HINT:

Arrange the removed parts in the correct order.

Fig 73: Prying Out Main Bearing Caps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT THRUST WASHER SET
1. Remove the upper bearings and upper thrust washers from the cylinder block.
  
  Fig 74: Locating 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. Using a piston ring expander, remove the 2 side rails.
3. Remove the oil ring expander by hand.
  HINT:
  
  Arrange the piston rings in the correct order.
  
  Fig 75: Removing Side Rails
  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 76: Checking 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 77: Prying Off Snap Rings From Piston
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Gradually heat the piston to approximately 80°C (176°F).
    
    Fig 78: 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 79: Tapping Out Piston Pin
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a gasket scraper, remove the carbon from the piston top.
  
  Fig 80: 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 81: 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 82: Cleaning Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SUB-ASSEMBLY OIL NOZZLE NO. 1
1. Using a 5 mm hexagon wrench, remove the 3 oil nozzles.
2. Check the oil nozzles for damage or clogging. If necessary, replace the oil nozzle.