Engine Unit: Disassembly: Disassembly

1. Remove the oil filler cap and gasket.

1. Remove the radiator cap.

1. Remove the drain plug and gasket.

1. Remove the ventilation valve.
   Fig 1: Identifying Ventilation Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 4 bolts and 4 sensors.
   Fig 2: Identifying VVT Sensor & Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 4 bolts and 4 oil control valves.
   Fig 3: Identifying Bolts & Oil Control Valves

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and sensor.
   Fig 4: Identifying Sensor Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the oil check valve bolt, oil pipe union and oil pipe.
   Fig 5: Locating No. 1 Oil Pipe And Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the oil control valve filter LH and gaskets.

1. Remove the oil check valve bolt, oil pipe union and oil pipe.
   Fig 6: Locating Oil Pipe Union And Oil Pipe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the oil control valve filter RH and gaskets.

1. Remove the water drain cocks from the cylinder block.
   Fig 7: Locating Cylinder Block Water Drain Cock Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the water drain cock plugs from the water drain cocks.

1. Using SST, remove the oil filter cap.
   Fig 8: View Of Removing Oil Filter Cap Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09228-06501 

   HINT: 

   Place a container for oil to be drained before removing the cap.

2. Remove the oil filter element and O-ring from the oil filter cap.
   Fig 9: View Of 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.

1. Connect a hose with an inside diameter of 15 mm (0.59 in.) to the pipe.
   Fig 10: Connecting Hose With Inside Diameter To Pipe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the oil filter drain plug.
   Fig 11: Identifying Oil Filter Drain Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the pipe to the oil filter cap.
   Fig 12: Installing Pipe To Oil Filter Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   If the O-ring is removed with the drain plug, install the O-ring together with the pipe.

   HINT: 

   Use a container to catch the draining oil.

4. Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring, as shown in the illustration.
   Fig 13: Checking If Oil Is Drained From Oil Filter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, remove the oil filter cap.
   Fig 14: Removing Oil Filter Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09228-06501 
6. Remove the oil filter element and O-ring from the oil filter cap.
   Fig 15: View Of Oil Filter Element And O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   Be sure to remove the O-ring (for the cap) by hand, without using any tools, to prevent damage to the groove for the O-ring on the cap.

1. Remove the bolt, 2 nuts and oil filter bracket from the oil pan.
   Fig 16: Identifying Oil Filter Bracket Sub-Assembly (For 4WD)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gasket from the oil filter bracket.

1. Using SST, loosen the crankshaft pulley bolt.
   Fig 17: Loosening Crankshaft Pulley Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09213-70011 
     1. 09213-70020
   • SST: 09330-00021 
2. Using SST, remove the crankshaft pulley bolt and crankshaft pulley.
   Fig 18: Removing Crankshaft Pulley

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09950-50013 
     1. 09951-05010
     2. 09952-05010
     3. 09953-05020
     4. 09954-05021

1. Separate the 3 water by-pass hoses.
   Fig 19: Location of Water By-Pass Hoses

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 bolts, nut and water inlet.
   Fig 20: Identifying Water Inlet, Bolt And Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 O-rings.
   Fig 21: Identifying Water Inlet Housing Gasket And Water Outlet Pipe O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 3 water by-pass hoses.
   Fig 22: Identifying Water By-Pass Hoses

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 3 nuts and water inlet with thermostat.
   Fig 23: Location of Water Inlet With Thermostat Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gasket from the water inlet.

1. Remove the 2 bolts, 4 nuts and water by-pass joint.
   Fig 24: Identifying Water By-Pass Joint Bolts And Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 gaskets and O-ring.
   Fig 25: Location of Gaskets And O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 14 bolts, head cover and gasket.
   Fig 26: Location of Cylinder Head Cover Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 gaskets.
   Fig 27: Identifying Gaskets

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. For 4WD:
   1. Remove the 2 bolts, and No. 2 engine hanger.
2. Remove the 12 bolts, head cover and gasket.
   Fig 28: Identifying Cylinder Head Cover Sub-Assembly Bolts

   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.

3. Remove the 3 gaskets.
   Fig 29: Identifying Gaskets

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Pry up the claws of the ventilation baffle plate.
   Fig 30: Prying Up Claws Of Ventilation Baffle Plate

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   Do not deform the claws of the baffle plate more than necessary.

2. Remove the 6 gaskets from the cylinder head covers.
   NOTE:

   • As much as possible prevent the plug tube gaskets from being deformed. The removed gaskets will be used when reinstalling the gaskets.
   • Do not damage the connection of the cylinder head cover.

1. For 2WD:
   1. Remove the 15 bolts and 2 nuts.
      Fig 31: Identifying Oil Pan Sub-Assembly Bolts And Nuts (For 2WD)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. For 4WD:
   1. Remove the 14 bolts and 2 nuts.
      Fig 32: Identifying Oil Pan Sub-Assembly Bolts And Nuts (For 4WD)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. 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 33: View Of Oil Pan Separation Procedure

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   Be careful not to damage the contact surfaces of the oil pans.

1. Remove the 3 nuts, oil with strainer pipe and gasket.
   Fig 34: Identifying Oil With Strainer Pipe Sub-Assembly Nuts (For 4WD)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 16 bolts and 2 nuts.
   Fig 35: 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 36: Locating Oil Pan And Cylinder Block

   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 37: Location of O-Rings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. For 2WD:
   1. Remove the 3 nuts, oil strainer and gasket.
      Fig 38: Identifying Oil Strainer & Gasket Nuts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Remove the 8 bolts and baffle plate.
      Fig 39: Identifying Baffle Plate Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. For 4WD:
   1. Remove the bolt, 2 nuts, oil strainer and gasket.
      Fig 40: Identifying New Gasket & Oil Strainer (For 4WD)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Remove the 7 bolts and baffle plate.
      Fig 41: Identifying Baffle Plate (For 4WD)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 6 bolts.
   Fig 42: Identifying Engine Rear Oil Seal Retainer Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, pry out the oil seal retainer.
   Fig 43: Identifying Engine Rear Oil Seal Retainer

   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.

1. Place the oil seal retainer on wooden blocks.
   Fig 44: Identifying Engine Rear 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 oil seal.

   HINT: 

   Tape the screwdriver tip before use.

1. Remove the 16 bolts, water pump and gasket.
   Fig 45: Identifying Water Pump Assembly Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 16 bolts and 2 nuts as shown in the illustration.
   Fig 46: Identifying 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.
   Fig 47: Removing Timing Chain Cover By Prying Between Timing Chain Cover & Cylinder Head

   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 48: Location of Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, pry out the oil seal.
   Fig 49: Prying Out Oil Seal Using Screwdriver

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Tape the screwdriver tip before use.

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 50: Setting Timing Mark On Crank Angle Sensor Plate To RH Block Bore Center Line (TDC/Compression)

   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.
   Fig 51: Aligning Timing Marks Of Camshaft Timing Gears With Timing Marks Of Bearing Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.

1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
   Fig 52: Identifying Stopper Plate And Plunger

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
   Fig 53: Identifying Chain Tensioner Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the chain tensioner slipper.

1. Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket.
   Fig 54: Turning Crankshaft Counterclockwise 10Degrees

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the pulley set bolt.
3. Remove the chain from the crankshaft timing sprocket and place it on the crankshaft.
   Fig 55: Identifying Crankshaft Timing Sprocket

   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.
   Fig 56: Identifying Camshaft Timing Gear Setting Position

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the chain.

1. Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, sprocket and No. 1 idle gear shaft.
   Fig 57: View Of Removing Idle Sprocket Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts and vibration damper.
   Fig 58: Identifying No. 1 Chain Vibration Damper Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 vibration dampers.
   Fig 59: Identifying No. 2 Chain Vibration Dampers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the crankshaft timing sprocket from the crankshaft.
   Fig 60: Identifying Crankshaft Timing Sprocket, Keys & Crankshaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 pulley set keys from the crankshaft.

1. While raising the No. 2 chain tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix the No. 2 chain tensioner.
   Fig 61: Inserting Pin Into Hole To Hold 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 RH.
   Fig 62: View Of Loosening Flange Bolts Of Camshaft Timing Gear Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09922-10010 
   NOTE:

   • Be careful not to damage the cylinder head with SST.
   • 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 with a new one.
3. Remove the No. 2 chain.

1. Remove the bolt and No. 2 chain tensioner.
   Fig 63: Identifying No. 2 Chain Tensioner Component Bolt Location

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check that the camshafts are positioned as shown in the illustration.
   Fig 64: Identifying Camshafts Position

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen and remove the 9 bearing cap bolts in the sequence shown in the illustration.
   Fig 65: Identifying Removal Sequence Of Bearing Cap Bolts (1 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Uniformly loosen and remove the 14 bearing cap bolts in the sequence shown in the illustration.
   Fig 66: Identifying Removal Sequence Of Bearing Cap Bolts (2 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   Uniformly loosen the bolts while keeping the camshaft level.

4. Remove the 6 bearing caps.

1. Remove the camshaft.

1. Remove the No. 2 camshaft.

1. Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver.
   Fig 67: Locating 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.

1. While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix the No. 3 chain tensioner.
   Fig 68: 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 69: Tightening Flange Bolts Of Camshaft Timing Gear Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09922-10010 
   NOTE:

   • Be careful not to damage the cylinder head with SST.
   • 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 with a new one.
3. Remove the No. 2 chain.

1. Remove the bolt and No. 3 chain tensioner.
   Fig 70: Identifying No. 3 Chain Tensioner Bolt Location

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check that the camshafts are positioned as shown in the illustration.
   Fig 71: Identifying Camshafts Position

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
   Fig 72: Identifying Removal Sequence Of Bearing Cap Bolts (1 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Uniformly loosen and remove the 13 bearing cap bolts in the sequence shown in the illustration.
   Fig 73: Identifying Removal Sequence Of Bearing Cap Bolts (2 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   Uniformly loosen the bolts while keeping the camshaft level.

4. Remove the 5 bearing caps.

1. Remove the No. 3 camshaft.

1. Remove the No. 4 camshaft.

1. Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.
   Fig 74: Removing Camshaft Housing Sub-Assembly LH

   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.

1. Remove the 24 valve rocker arms.
   Fig 75: Identifying Valve Rocker Arms

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Arrange the removed parts in the correct order.

1. Remove the 24 valve lash adjusters from the cylinder head.

   HINT: 

   Arrange the removed parts in the correct order.

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 76: Removing Cylinder Head Sub-Assembly Bolts In Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Be careful not to drop washers into the cylinder head.
   • Cylinder head warpage or cracking could result from removing bolts in an incorrect order.

   HINT: 

   Be sure to keep separate the removed parts for each installation position.

2. Remove the cylinder head and gasket.

1. Uniformly loosen and remove the bolts in the sequence shown in the illustration.
   Fig 77: Removing Bolts In 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 78: Removing Cylinder Head Bolts And Plate Washers In Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Be careful not to drop washers into the cylinder head.
   • Cylinder head warpage or cracking could result from removing bolts in an incorrect order.

   HINT: 

   Be sure to keep separate the removed parts for each installation position.

3. Remove the cylinder head and gasket.

1. Using needle-nose pliers, remove the cylinder block water jacket spacer RH.
   Fig 79: Removing Cylinder Block Water Jacket Spacer RH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   Be sure to remove the water jacket spacer if turning the cylinder block.

1. Using needle-nose pliers, remove the cylinder block water jacket spacer LH.
   NOTE:

   Be sure to remove the water jacket spacer if turning the cylinder block.

1. Disconnect the knock sensor wire.
   Fig 80: Identifying Knock Sensor

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the 2 knock sensor connectors.
3. Remove the 2 bolts and knock sensors.
   Fig 81: Identifying Knock Sensors Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts and water outlet pipe.
   Fig 82: Identifying Water Outlet Pipe Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the valve stem caps from the cylinder heads.

   HINT: 

   Arrange the removed parts in the correct order.

1. Using SST, compress the compression spring and remove the valve spring retainer locks.
   Fig 83: Removing/Installing Retainer Locks Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09202-70020 
     1. 09202-00010
2. Remove the retainer, compression spring and valve.

   HINT: 

   Arrange the removed parts in the correct order.

1. Using SST, compress the compression spring and remove the valve spring retainer locks.
   Fig 84: View Of Removing Exhaust Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09202-70020 
     1. 09202-00010
2. Remove the retainer, compression spring and valve.

   HINT: 

   Arrange the removed parts in the correct order.

1. Using needle-nose pliers, remove the oil seals.
   Fig 85: View Of Removing Valve Stem Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using compressed air and a magnetic finger, remove the valve spring seats by blowing air onto them.
   Fig 86: Removing Valve Spring Seats

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a 10 mm hexagon wrench, remove the 4 screw plugs and 4 gaskets.
   Fig 87: Identifying Screw Plugs & Gaskets

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   If water leaks from the straight screw plug or the plug corrodes, replace it.

1. Using a 14 mm hexagon wrench, remove the screw plugs and gaskets.
   Fig 88: Locating No. 2 Straight Screw Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   If water leaks from the straight screw plug or the plug corrodes, replace it.

1. Remove the unions from the cylinder heads.

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 89: View Of Removing Intake Valve Guide Bush

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09201-10000 
     1. 09201-01050
   • SST: 09950-70010 
     1. 09951-07100

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 90: Tapping Out Intake Valve Guide Bushes

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09201-10000 
     1. 09201-01050
   • SST: 09950-70010 
     1. 09951-07100

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.
3. Using the 2 removed connecting rod caps 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.

4. Using a ridge reamer, remove all the carbon from the top of the cylinder.
   Fig 91: Removing Carbon From Top Of Cylinder

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

   HINT: 

   • Keep the bearing, connecting rod and cap together.
   • Arrange the piston and connecting rod assemblies in the correct order.

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 92: Removing Main Bearing Cap Bolts In 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 93: Removing Bearing Cap Bolts In 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 94: 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 until the cap can be removed.
   • Be careful not to damage the joint surface of the cylinder block and the main bearing cap.
4. Remove the crankshaft.

HINT: 

Arrange the removed parts in the correct order.

1. Remove the upper bearings and upper thrust washers from the cylinder block.
   Fig 95: Identifying Upper Bearings And Upper Thrust Washers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a piston ring expander, remove the 2 compression rings.
   Fig 96: Removing Piston Rings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a piston ring expander, remove the oil ring rail.
3. Remove the oil ring expander by hand.

   HINT: 

   Arrange the removed parts in the correct order.

1. Disconnect the connecting rod from the piston.
   Fig 97: View Of Removing Snap Rings From Piston

   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 98: 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 99: View Of 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.
2. Using a gasket scraper, remove the carbon from the piston top.
   Fig 100: View Of Removing Carbon From Piston Top

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
   Fig 101: View Of Cleaning Piston Ring Grooves

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using solvent and a brush, thoroughly clean the piston.
   Fig 102: View Of Cleaning Piston

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   Do not use a wire brush.

1. Using a 5 mm hexagon wrench, remove the bolts and oil nozzles.
   Fig 103: Identifying Bolt And No. 1 Oil Nozzle

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the 3 oil nozzles for damage or clogging.

1. Using SST and press, press out the bush.
   Fig 104: Pressing In Bush Using SST & Press

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09222-30010