Engine Unit: Disassembly: Disassembly

WARNING: This page is about a different car, the 2011 Toyota Avalon. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE OIL FILLER CAP SUB-ASSEMBLY
1. Remove the oil filler cap sub-assembly and oil filler gasket.
REMOVE SPARK PLUG
1. Remove the spark plugs.
REMOVE OIL PAN DRAIN PLUG
1. Remove the oil pan drain plug and oil pan drain plug gasket.
  
  Fig 1: Locating 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: Locating Bolts And Camshaft Position Sensors
  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 Bolts And Camshaft Oil Control Valves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT POSITION SENSOR
1. Remove the bolt and crankshaft position 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, gaskets and oil pipe.
  
  Fig 6: Locating Oil Pipe Unions And Oil Pipe No. 1
  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: Locating Oil Pipe Bolt
  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: Cylinder Block Water Drain Cocks
  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: Locating 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 sub-assembly.
  
  Fig 11: Removing Oil Filter Cap Using 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: Loosening Crankshaft Pulley Bolt Using 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: Removing Crankshaft Pulley Using 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: Locating Engine Mounting Bracket Front And 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: Locating Water Inlet With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gasket.
3. Remove the drain cock plug.
4. Remove the drain cock assembly.
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 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 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, seal washer, cylinder head cover sub-assembly LH and cylinder head cover gasket LH.
  
  Fig 21: Locating Bolts, Seal Washer, Head Cover And Gasket
  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.
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
1. Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.
  
  Fig 22: Locating Bolts, Head Cover And Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
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 oil pan seal cutter blade between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.
  
  Fig 24: 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 25: 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 26: 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 sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly with a screwdriver.
  
  Fig 27: Locating Between 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 28: Locating 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 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: Identifying Engine Rear Oil Seal Retainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, pry out the oil seal retainer.
  
  Fig 31: Prying Out Oil Seal Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE WATER PUMP ASSEMBLY
1. Remove the 16 bolts, water pump assembly and gasket.
  
  Fig 32: 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 33: Locating Timing Chain Cover Bolts And 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 sub-assembly or cylinder block sub-assembly with a screwdriver.
  
  Fig 34: Removing Bolts, Chain Cover Plate And 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 chain cover plate gasket.
4. Remove the gasket.
  
  Fig 35: Identifying Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SET NO. 1 CYLINDER TO TDC / COMPRESSION
1. Temporarily tighten the pulley set bolt.
  
  Fig 36: Identifying Timing Mark On Crank Angle Sensor Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC / compression).
3. Check that the timing marks of the camshaft timing gears are aligned with those of the bearing cap as shown in the illustration.
  
  Fig 37: 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 38: 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 39: 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 sub-assembly of the crankshaft timing sprocket.
  
  Fig 40: 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 41: Identifying Chain Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Turn the camshaft timing gear assembly on the bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the banks.
  
  Fig 42: Identifying Camshaft Timing Gear Assembly 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, idle sprocket assembly and No. 1 idle gear shaft.
  
  Fig 43: Locating Idle Gear Shaft No. 2, Idle Sprocket And 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 44: Locating Chain Vibration Damper With 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 GEAR
1. Remove the crankshaft timing sprocket from the crankshaft.
  
  Fig 45: Identifying Crankshaft Timing Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 keys from the crankshaft.
REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)
1. While raising the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.039 in.) into the hole to fix the No. 2 chain tensioner.
  
  Fig 46: Inserting Pin Into Hole For Fixing 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 47: Loosening Flange Bolts Of Camshaft Timing Gear Assembly Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09922-10010
  NOTE:
  Do not loosen the other bolt. If any of the 4 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 48: Locating Chain Tensioner No. 2 Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT BEARING CAP
1. Remove the 3 gaskets.
  
  Fig 49: Identifying Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that the camshafts are positioned as shown in the illustration.
  
  Fig 50: Identifying Knock Pin Of Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
  
  Fig 51: Identifying Bearing Cap Bolts Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Uniformly loosen and remove the 12 bearing cap bolts in the sequence shown in the illustration.
  
  Fig 52: Locating Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
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 53: 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 Bank 2)
1. While pushing down the No. 3 chain tensioner assembly, insert a pin of 1.0 mm (0.039 in.) into the hole to fix the No. 3 chain tensioner assembly.
  
  Fig 54: 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 55: Identifying Flange Bolts Of The Camshaft Timing Gear Assembly And Timing Exhaust Gear Assembly Components LH Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09922-10010
  NOTE:
  Do not loosen the other bolt. If any of the 4 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 56: Locating Chain Tensioner No. 3 Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT BEARING CAP
1. Remove the 3 gaskets.
  
  Fig 57: Locating Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that the camshafts are positioned as shown in the illustration.
  
  Fig 58: Identifying Knock Pin Of Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
  
  Fig 59: Identifying Bearing Cap Bolts Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Uniformly loosen and remove the 13 bearing cap bolts in the sequence shown in the illustration.
  
  Fig 60: Locating Bearing Cap Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
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 61: Prying Between Cylinder Head And Camshaft Housing
  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 sub-assemblies.
  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 LH
1. Uniformly loosen and remove the cylinder head set bolts in the sequence shown in the illustration.
  
  Fig 62: Identifying Cylinder Head Sub-Assembly Bolts Loosening Sequence
  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.
  
  Fig 63: Identifying Cylinder Head Bolts Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 separate the removed parts for each installation position.
3. Remove the cylinder head sub-assembly LH and No. 2 cylinder head gasket.
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.
  
  Fig 64: Locating Cylinder Head Bolts And Plate Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 separate the removed parts for each installation position.
2. Remove the cylinder head sub-assembly RH and cylinder head gasket.
REMOVE WATER INLET PIPE
1. Remove the 2 clamps and separate the No. 1 water bypass hose.
  
  Fig 65: Locating Water By-Pass Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts and water inlet pipe.
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 66: Compressing Inner Compression Spring To Remove Valve Spring Retainer Locks Using SST
  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 67: Compressing Inner Compression Spring To Remove Valve Spring Retainer Locks Using SST
  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 oil seals.
  
  Fig 68: Removing Oil Seals
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE SPRING SEAT
1. Using compressed air and a magnetic pick-up tool, remove the valve spring seats by blowing air onto them.
  
  Fig 69: Removing Valve Spring Seat By Blowing Air
  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 70: Locating No. 1 Straight Screw Plugs And 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 2 No. 2 straight screw plugs and 2 gaskets.
  
  Fig 71: Locating No. 2 Straight Screw Plugs And 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 STRAIGHT PIN
NOTE:
If the straight pin is deformed or the threads are damaged, replace it.
REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
  
  Fig 72: Removing Carbon From Top Of Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
REMOVE CONNECTING ROD BEARING
HINT:

Arrange the removed parts in the correct order.
REMOVE CRANKSHAFT
1. Uniformly loosen and remove the 8 crankshaft bearing cap bolts and seal washers in several steps and in the sequence shown in the illustration.
  
  Fig 73: 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 74: 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 75: 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 surface of the cylinder block and the main bearing cap.
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 76: 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 77: 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 78: Checking Fitting Condition Between Piston And 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.
  
  Fig 79: Prying Off Snap Rings From Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using a screwdriver, pry off the piston pin hole snap rings from the piston.
  2. Gradually heat the piston to approximately 80°C (176°F).
    
    Fig 80: Heat The Piston 80DegreesC (176DegreesF)
    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 81: 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 82: 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 83: Cleaning Piston Ring Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using solvent and a brush, thoroughly clean the piston.
  
  Fig 84: 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 85: Locating Oil Nozzles
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the 3 oil nozzles for damage or clogging.
  If necessary, replace the No. 1 oil nozzle sub-assembly.