Engine Unit: Disassembly

CAUTION: For additional information on timing chain/gear removal guidelines, installtion and camshaft timing gear alignment, see 2GR-FE, 2GR-FSE, 3GR-FSE, 4GR-FSE VALVE TIMING PROCEDURE .

REMOVE OIL FILLER CAP SUB-ASSEMBLY
1. Remove the oil filler cap and gasket.
REMOVE RADIATOR CAP SUB-ASSEMBLY
1. Remove the radiator cap.
REMOVE SPARK PLUG
REMOVE OIL PAN DRAIN PLUG
1. Remove the drain plug and gasket.
REMOVE VENTILATION VALVE SUB-ASSEMBLY
1. Remove the ventilation valve.
  
  Fig 1: Locating Ventilation Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT POSITION SENSOR
1. Remove the 4 bolts and 4 sensors.
  
  Fig 2: Locating Camshaft Position Sensor Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
1. Remove the 4 bolts and 4 oil control valves.
  
  Fig 3: Locating Oil Control Valves Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT POSITION SENSOR
1. Remove the bolt and sensor.
  
  Fig 4: Locating Sensor Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 OIL PIPE
1. Remove the oil check valve bolt, oil pipe union and oil pipe.
2. Remove the oil control valve filter LH and gaskets.
  
  Fig 5: Locating No. 1 Oil Pipe And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 OIL PIPE
1. Remove the oil check valve bolt, oil pipe union and oil pipe.
2. Remove the oil control valve filter RH and gaskets.
  
  Fig 6: Locating Oil Pipe Union And Oil Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Remove the water drain cocks from the cylinder block.
2. Remove the water drain cock plugs from the water drain cocks.
  
  Fig 7: Locating Cylinder Block Water Drain Cock Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL FILTER ELEMENT (for 2WD)
1. Using SST, remove the oil filter cap.
  SST 09228-06501
  
  HINT:
  
  Place a container for oil to be drained before removing the cap.
  
  Fig 8: Identifying Oil Filter Cap With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. 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 9: Identifying Oil Filter Element And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL FILTER ELEMENT (for 4WD)
1. Connect a hose with an inside diameter of 15 mm (0.59 in.) to the pipe.
  
  Fig 10: Removing Oil Filter Element (For 4WD)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the oil filter drain plug.
  
  Fig 11: Locating Oil Filter Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the pipe to the oil filter cap.
  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.
  
  Fig 12: Identifying Oil Filter Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Oil Drained Of Oil Filter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, remove the oil filter cap.
  SST 09228-06501
  
  Fig 14: 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: 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.
  
  Fig 15: Identifying Oil Filter Element And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL FILTER BRACKET (for 4WD)
1. Remove the bolt, 2 nuts and oil filter bracket from the oil pan.
2. Remove the gasket from the oil filter bracket.
  
  Fig 16: Locating Oil Filter Bracket Bolts And Nuts
  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 17: 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 18: Removing Crankshaft Pulley Bolt And Crankshaft Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER INLET ASSEMBLY
1. Separate the 3 water by-pass hoses.
  
  Fig 19: Locating Water By-Pass Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 bolts, nut and water inlet.
  
  Fig 20: Locating Water Inlet, Bolts And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 O-rings.
  
  Fig 21: Locating O-rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 3 water by-pass hoses.
  
  Fig 22: Locating Water By-Pass Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY
1. Remove the 3 nuts and water inlet with thermostat.
2. Remove the gasket from the water inlet.
  
  Fig 23: Locating Water Inlet With Thermostat Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR WATER BY-PASS JOINT
1. Remove the 2 bolts, 4 nuts and water by-pass joint.
  
  Fig 24: Locating Water By-Pass Joint, Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 gaskets and O-ring.
  
  Fig 25: Locating Gaskets And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)
1. Remove the 14 bolts, head cover and gasket.
  
  Fig 26: Locating Cylinder Head Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 gaskets.
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
1. For 4WD:
  1. Remove the 2 bolts, and No. 2 engine hanger.
    
    Fig 27: Locating Cylinder Head Cover And Gasket
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 12 bolts, head cover and gasket.
  NOTE: The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the head cover.
  
  Fig 28: Locating Head Cover And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 gaskets.
  
  Fig 29: Locating Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPARK PLUG TUBE GASKET
1. Pry up the claws of the ventilation baffle plate.
  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.
    
    Fig 30: Removing Spark Plug Tube Gasket
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
1. For 2WD:
  1. Remove the 15 bolts and 2 nuts.
    
    Fig 31: Locating Oil Pan And Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. For 4WD:
  1. Remove the 14 bolts and 2 nuts.
    
    Fig 32: Locating Oil Pan And Bolts (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.
  NOTE: Be careful not to damage the contact surfaces of the oil pans.
  
  Fig 33: Removing No. 2 Oil Pan Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL WITH STRAINER PIPE SUB-ASSEMBLY (for 4WD)
1. Remove the 3 nuts, oil with strainer pipe and gasket.
  
  Fig 34: Locating Oil With Strainer Pipe Sub-Assembly (For 4WD)
  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 35: Locating Oil Pan, 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 36: Locating Oil Pan And Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 O-rings.
  
  Fig 37: Locating O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL STRAINER SUB-ASSEMBLY
1. For 2WD:
  1. Remove the 3 nuts, oil strainer and gasket.
    
    Fig 38: Locating Oil Strainer And Nuts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove the 8 bolts and baffle plate.
    
    Fig 39: Locating Baffle Plate And Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. For 4WD:
  1. Remove the bolt, 2 nuts, oil strainer and gasket.
    
    Fig 40: Locating Oil Strainer, Bolts And Nuts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove the 7 bolts and baffle plate.
    
    Fig 41: Locating Baffle Plate And Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE REAR OIL SEAL RETAINER
1. Remove the 6 bolts.
  
  Fig 42: Locating Engine Rear Oil Seal Retainer And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, pry out the oil seal retainer.
  NOTE: Be careful not to damage the engine rear oil seal retainer.
  
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 43: Prying Oil Seal Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE REAR OIL SEAL
1. Place the oil seal retainer on wooden blocks.
  NOTE: Be careful not to damage the engine rear oil seal retainer.
2. Using a screwdriver and a hammer, tap out the oil seal.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 44: Tapping Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER PUMP ASSEMBLY
1. Remove the 16 bolts, water pump and gasket.
  
  Fig 45: Locating Water Pump And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
1. Remove the 16 bolts and 2 nuts as shown in the illustration.
  
  Fig 46: Locating Timing Chain Cover, Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.
  NOTE: Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.
  
  HINT:
  
  Tape the screwdriver tip before use.
3. Remove the 4 bolts, chain cover plate and gasket.
  
  Fig 47: Removing Timing Chain Cover With Prying
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the gasket.
  
  Fig 48: Locating Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TIMING CHAIN CASE OIL SEAL
1. Using a screwdriver, pry out the oil seal.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 49: Removing Timing Chain Case Oil Seal
  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, 2GR-FSE, 3GR-FSE, 4GR-FSE 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 50: 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 51: 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.
  
  Fig 52: Removing No. 1 Chain Tensioner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 bolts and chain tensioner.
REMOVE CHAIN TENSIONER SLIPPER
1. Remove the chain tensioner slipper.
REMOVE CHAIN SUB-ASSEMBLY
1. Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket.
2. Remove the pulley set bolt.
  
  Fig 54: Identifying Crankshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the chain from the crankshaft timing sprocket and place it on the crankshaft.
  
  Fig 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.
5. Remove the chain.
  
  Fig 56: Identifying Camshaft Timing Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE IDLE SPROCKET ASSEMBLY
1. Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, sprocket and No. 1 idle gear shaft.
  
  Fig 57: Removing Idle Sprocket Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN VIBRATION DAMPER
1. Remove the 2 bolts and vibration damper.
  
  Fig 58: Locating Vibration Damper And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CHAIN VIBRATION DAMPER
1. Remove the 2 vibration dampers.
  
  Fig 59: Locating Vibration Dampers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT TIMING SPROCKET
1. Remove the crankshaft timing sprocket from the crankshaft.
2. Remove the 2 pulley set keys from the crankshaft.
  
  Fig 60: Identifying Crankshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)
1. While raising the No. 2 chain tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix the No. 2 chain tensioner.
  
  Fig 61: Removing Camshaft Timing Gears And No. 2 Chain (For Bank 1)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.
  NOTE:
  - Be careful not to damage the cylinder head with the wrench.
  - Do not disassemble the camshaft timing gear assemblies.
3. Remove the No. 2 chain.
  
  Fig 62: Holding Hexagonal Portion Of Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
1. Remove the bolt and No. 2 chain tensioner.
  
  Fig 63: Locating No. 2 Chain Tensioner Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT BEARING CAP (for Bank 1)
1. Check that the camshafts are positioned as shown in the illustration.
  
  Fig 64: Identifying Camshaft Bearing Cap
  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: Locating Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Uniformly loosen and remove the 14 bearing cap bolts in the sequence shown in the illustration.
  NOTE: Uniformly loosen the bolts while keeping the camshaft level.
4. Remove the 6 bearing caps.
REMOVE CAMSHAFT
1. Remove the camshaft.
REMOVE NO. 2 CAMSHAFT
1. Remove the No. 2 camshaft.
  
  Fig 66: Locating 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 67: Locating Camshaft Housing Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)
1. While pushing down the No. 3 chain tensioner, insert a pin of Ø 1.0 mm (0.039 in.) into the hole to fix the No. 3 chain tensioner.
  
  Fig 68: Pushing No. 3 Chain Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.
  NOTE:
  - Be careful not to damage the cylinder head with the wrench.
  - Do not disassemble the camshaft timing gear assemblies.
3. Remove the No. 2 chain.
  
  Fig 69: Holding Hexagonal Portion Of Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
1. Remove the bolt and No. 3 chain tensioner.
  
  Fig 70: Locating No. 3 Chain Tensioner Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT BEARING CAP (for Bank 2)
1. Check that the camshafts are positioned as shown in the illustration.
  
  Fig 71: Identifying Camshaft Bearing Cap (For Bank 2)
  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: Locating Bearing Cap Bolts Loosen Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Uniformly loosen and remove the 13 bearing cap bolts in the sequence shown in the illustration.
  NOTE: Uniformly loosen the bolts while keeping the camshaft level.
4. Remove the 5 bearing caps.
  
  Fig 73: Locating Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 CAMSHAFT
1. Remove the No. 3 camshaft.
REMOVE NO. 4 CAMSHAFT
1. Remove the No. 4 camshaft.
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH
1. Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.
  NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.
  
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 74: Identifying Camshaft Housing Sub-Assembly LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Remove the 24 valve rocker arms.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE VALVE LASH ADJUSTER ASSEMBLY
1. Remove the 24 valve lash adjusters from the cylinder head.
  HINT:
  
  Arrange the removed parts in the correct order.
  
  Fig 75: Removing Valve Lash Adjuster Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD SUB-ASSEMBLY RH
1. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
  NOTE:
  - Be careful not to drop washers into the cylinder head.
  - Cylinder head warpage or cracking could result from removing bolts in an incorrect order.
    
    Fig 76: Locating Cylinder Head Bolts Loosen Sequence
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  HINT:
  
  Be sure to keep separate the removed parts for each installation position.
2. Remove the cylinder head and gasket.
REMOVE CYLINDER HEAD SUB-ASSEMBLY LH
1. Uniformly loosen and remove the bolts in the sequence shown in the illustration.
  
  Fig 77: Locating Cylinder Head Bolts Loosen 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.
  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.
  
  Fig 78: Identifying Camshaft Housing Sub-Assembly LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the cylinder head and gasket.
REMOVE CYLINDER BLOCK WATER JACKET SPACER RH
1. Using needle-nose pliers, remove the cylinder block water jacket spacer RH.
  NOTE: Be sure to remove the water jacket spacer if turning the cylinder block.
  
  Fig 79: Identifying Cylinder Block Water Jacket Spacer RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER BLOCK WATER JACKET SPACER LH
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.
REMOVE KNOCK SENSOR
1. Disconnect the knock sensor wire.
2. Disconnect the 2 knock sensor connectors.
  
  Fig 80: Identifying Knock Sensor Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 bolts and knock sensors.
  
  Fig 81: Identifying Knock Sensor Connectors And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER OUTLET PIPE SUB-ASSEMBLY
1. Remove the 2 bolts and water outlet 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, compress the compression spring and remove the valve spring retainer locks.
  SST 09202-70020 (09202-00010)
2. Remove the retainer, compression spring and valve.
  HINT:
  
  Arrange the removed parts in the correct order.
  
  Fig 83: Removing Intake Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST VALVE
1. Using SST, compress the compression spring and remove the valve spring retainer locks.
  SST 09202-70020(09202-00010)
2. Remove the retainer, compression spring and valve.
  HINT:
  
  Arrange the removed parts in the correct order.
  
  Fig 84: Removing Exhaust Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE STEM OIL SEAL
1. Using needle-nose pliers, remove the oil seals.
  
  Fig 85: Locating Valve Stem Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE SPRING SEAT
1. Using compressed air and a magnetic finger, remove the valve spring seats by blowing air onto them.
  
  Fig 86: Removing Valve Spring Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 STRAIGHT SCREW PLUG
1. Using a 10 mm hexagon wrench, remove the 4 screw plugs and 4 gaskets.
  NOTE: If water leaks from the straight screw plug or the plug corrodes, replace it.
  
  Fig 87: Locating No. 1 Straight Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 STRAIGHT SCREW PLUG
1. Using a 14 mm hexagon wrench, remove the screw plugs and gaskets.
  NOTE: If water leaks from the straight screw plug or the plug corrodes, replace it.
REMOVE UNION
1. Remove the unions from the cylinder heads.
REMOVE RING PIN
NOTE: It is not necessary to remove the ring pin unless it is being replaced.
REMOVE STUD BOLT
NOTE: If the stud bolt is deformed or the threads are damaged, replace it.
REMOVE INTAKE VALVE GUIDE BUSH
1. Heat the cylinder head to 80 to 100°C (176 to 212°F).
2. Place the cylinder head on wooden blocks.
3. Using SST and a hammer, tap out the guide bushes.
  SST 09201 -10000 (09201 -01050), 09950-70010 (09951-07100)
  
  Fig 89: Tapping Guide Bushes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST VALVE GUIDE BUSH
1. Heat the cylinder head to 80 to 100°C (176 to 212°F).
2. Place the cylinder head on wooden blocks.
3. Using SST and a hammer, tap out the guide bushes.
  SST 09201 -10000 (09201 -01050), 09950-70010 (09951-07100)
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.
  
  Fig 90: Tapping Guide Bushes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
5. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
  HINT:
  - Keep the bearing, connecting rod and cap together.
  - Arrange the piston and connecting rod assemblies in the correct order.
    
    Fig 91: Removing Carbon Top Of Cylinder With Ridge Reamer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONNECTING ROD BEARING
NOTE: 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 92: Locating Crankshaft 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 93: Locating Bearing Cap Bolts Loosen 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.
  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.
REMOVE CRANKSHAFT BEARING
HINT:

Arrange the removed parts in the correct order.

Fig 94: Removing Main Bearing Cap And Bolts
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 95: 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 oil ring rail.
3. Remove the oil ring expander by hand.
  HINT:
  
  Arrange the removed parts in the correct order.
  
  Fig 96: Removing Piston Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON SUB-ASSEMBLY WITH PIN
1. Disconnect the connecting rod from the piston.
  1. Using a screwdriver, pry off the snap rings from the piston.
    
    Fig 97: Removing Piston Sub-Assembly With Pin
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
    HINT:
    - The piston and pin are a matched set.
    - Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
      
      Fig 99: Removing Connecting Rod
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a gasket scraper, remove the carbon from the piston top.
  
  Fig 100: Removing Carbon Of Piston Top
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
  
  Fig 101: Cleaning Piston Ring Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using solvent and a brush, thoroughly clean the piston.
  NOTE: Do not use a wire brush.
  
  Fig 102: Cleaning Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm hexagon wrench, remove the bolts and oil nozzles.
2. Check the 3 oil nozzles for damage or clogging.
  
  Fig 103: Locating Oil Nozzles Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONNECTING ROD SMALL END BUSH
1. Using SST and press, press out the bush.
  SST 09222-30010
  
  Fig 104: Removing Connecting Rod Small End Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002