Engine Unit: Disassembly

WARNING: This page is about a different car, the 2006 Lexus IS 350. 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, 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: Identifying Ventilation Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT POSITION SENSOR
1. Remove the 4 bolts and 4 sensors.
  
  Fig 2: Identifying Camshaft Position Sensor
  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: Identifying Camshaft Timing Oil Control Valve Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT POSITION SENSOR
1. Remove the bolt and sensor.
  
  Fig 4: Locating Crankshaft Position Sensor Removing 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 Oil Pipe Union And Oil Check Valve Bolt
  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 Check Valve Bolt
  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 Water Drain Cocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL FILTER ELEMENT
1. Using SST, remove the oil filter cap.
  SST 09228-06501
  
  Fig 8: Removing Oil Filter Cap Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
REMOVE CRANKSHAFT PULLEY
1. Using SST, loosen the crankshaft pulley bolt.
  
  Fig 10: Loosening Crankshaft Pulley Bolt Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09213-70011 (09213-70020), 09330-00021
2. Using SST, remove the crankshaft pulley bolt and crankshaft pulley.
  
  Fig 11: Removing Crankshaft Pulley Bolt And Crankshaft Pulley Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
REMOVE WATER INLET ASSEMBLY
1. Separate the 3 water by-pass hoses.
  
  Fig 12: Identifying 3 Water By-Pass Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 bolts, nut and water inlet.
  
  Fig 13: Identifying Water Inlet Removing Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 O-rings.
  
  Fig 14: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 3 water by-pass hoses.
  
  Fig 15: Identifying 3 Water By-Pass Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER INLET WITH THERMOSTAT SUBASSEMBLY
1. Remove the 3 nuts and water inlet with thermostat.
2. Remove the gasket from the water inlet.
  
  Fig 16: Identifying 3 Nuts
  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 17: Identifying Rear Water By-Pass Joint Removing Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 gaskets and O-ring.
  
  Fig 18: Locating 2 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 19: Identifying Bolts, Head Cover And Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 gaskets.
  
  Fig 20: Identifying Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)
1. Remove the 12 bolts, head cover and gasket.
  
  Fig 21: Locating 12 Bolts And Baffle Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the head cover.
2. Remove the 3 gaskets.
  
  Fig 22: Identifying 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.
  
  Fig 23: Prying Up Claws Of Ventilation Baffle Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
1. Remove the 15 bolts and 2 nuts.
  
  Fig 24: Identifying 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 No. 2 oil pan sub-assembly.
  
  Fig 25: Inserting Blade Of SST Between Oil Pans
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09032-00100
  
  NOTE: Be careful not to damage the contact surfaces of the oil pans.
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 by prying between the oil pan and cylinder block with a screwdriver.
  
  Fig 27: Removing Oil Pan By Prying Between 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 28: Locating O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL STRAINER SUB-ASSEMBLY
1. Remove the 3 nuts, oil strainer and gasket.
  
  Fig 29: Identifying Oil Strainer Removing Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 8 bolts and baffle plate.
  
  Fig 30: Identifying Baffle Plate Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE REAR OIL SEAL RETAINER
1. Remove the 6 bolts.
  
  Fig 31: Identifying Engine Rear Oil Seal Retainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, pry out the oil seal retainer.
  
  Fig 32: Prying Out Oil Seal Retainer Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the engine rear oil seal retainer.
  
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE ENGINE REAR OIL SEAL
1. Place the oil seal retainer on wooden blocks.
  
  Fig 33: 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.
REMOVE WATER PUMP ASSEMBLY
1. Remove the 16 bolts, water pump and gasket.
  
  Fig 34: Identifying Water Pump 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 35: Identifying 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 36: Identifying Timing Chain Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the gasket.
  
  Fig 37: 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 38: Removing Timing Chain Case Oil Seal Using Screwdriver
  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 39: Setting Timing Mark On Crank Angle Sensor Plate To RH Block Bore Center Line
  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 40: Identifying Timing Marks Of Camshaft Timing Gears And Bearing Cap
  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 pin of 1.27 mm (0.05 in.) into the stopper plate's hole.
  
  Fig 41: Identifying No.1 Chain Tensioner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 bolts and chain tensioner.
Fig 42: Identifying Chain Tensioner 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 of the crankshaft timing sprocket.
2. Remove the pulley set bolt.
  
  Fig 43: Identifying Chain Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the chain from the crankshaft timing sprocket and place it on the crankshaft.
  
  Fig 44: Locating Chain
  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 45: Camshaft Timing Gear Setting Position
  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 46: Identifying Idle Sprocket Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 CHAIN VIBRATION DAMPER
1. Remove the 2 bolts and vibration damper.
  
  Fig 47: Identifying No.1 Chain Vibration Damper Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CHAIN VIBRATION DAMPER
1. Remove the 2 vibration dampers.
  
  Fig 48: Identifying No.2 Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT TIMING SPROCKET
1. Remove the crankshaft timing sprocket from the crankshaft.
  
  Fig 49: Identifying Crankshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 pulley set keys from the crankshaft.
REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for 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 50: Identifying 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.
  
  Fig 51: Identifying Camshaft Timing Gear Assemblies
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
1. Remove the bolt and No. 2 chain tensioner.
  
  Fig 52: Identifying No.2 Chain Tensioner Bolt
  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 53: Identifying Position Of Camshafts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen and remove the 9 bearing cap bolts in the sequence shown in the illustration.
  
  Fig 54: Identifying Bearing Cap Bolts Loosening Sequence
  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.
  
  Fig 55: Identifying Bearing Cap Bolts Removing Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CAMSHAFT
1. Remove the camshaft.
REMOVE NO. 2 CAMSHAFT
1. Remove the No. 2 camshaft.
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH
1. Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver.
  
  Fig 56: Identifying Camshaft Housing Sub-Assembly RH
  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, insert a pin of 1.0 mm (0.039 in.) into the hole to fix the No. 3 chain tensioner.
  
  Fig 57: Identifying Camshaft Timing Gears And No.2 Chain (For Bank 2)
  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.
  
  Fig 58: Identifying 2 Bolts And 2 Camshaft Timing Gear Assemblies
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
1. Remove the bolt and No. 3 chain tensioner.
  
  Fig 59: Identifying 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 60: Identifying Position Of Camshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
  
  Fig 61: Identifying Bearing Cap Bolts Removing 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.
  
  Fig 62: Identifying Bearing Cap Bolts Removing Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 5 bearing caps.
REMOVE NO. 3 CAMSHAFT
1. Remove the No. 3 camshaft.
REMOVE NO. 4 CAMSHAFT
1. Remove the No. 4 camshaft.
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH
1. Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.
  
  Fig 63: Identifying 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.
REMOVE NO. 1 VALVE ROCKER ARM SUBASSEMBLY
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.
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: Identifying Cylinder Head Bolts Loosening Sequence (RH)
  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.
REMOVE CYLINDER HEAD SUB-ASSEMBLY LH
1. Uniformly loosen and remove the bolts in the sequence shown in the illustration.
  
  Fig 65: Identifying Cylinder Head Bolts Loosening Sequence (LH)
  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 66: Identifying Bolts Loosening 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.
REMOVE KNOCK SENSOR
1. Disconnect the knock sensor wire.
2. Disconnect the 2 knock sensor connectors.
  
  Fig 67: Identifying Knock Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 bolts and knock sensors.
  
  Fig 68: Identifying Knock Sensors Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER OUTLET PIPE SUB-ASSEMBLY
1. Remove the 2 bolts and water outlet pipe.
  
  Fig 69: Identifying Water Outlet Pipe Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE STEM CAP
1. Remove the valve stem caps from the cylinder heads.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE INTAKE VALVE
1. Using SST, compress the compression spring and remove the valve spring retainer locks.
  SST 09202-70020 (09202-00010)
2. Remove the retainer, compression spring and valve.
  
  Fig 70: Identifying Intake Valve And SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Arrange the removed parts in the correct order.
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.
  
  Fig 71: Identifying Exhaust Valve And SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE VALVE STEM OIL SEAL
1. Using needle-nose pliers, remove the oil seals.
  
  Fig 72: Removing Valve Stem Oil Seal Using Needle-Nose Pliers
  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 73: Identifying Valve Spring Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 STRAIGHT SCREW PLUG
1. Using a 10 mm hexagon wrench, remove the 4 screw plugs and 4 gaskets.
  
  Fig 74: Locating No.1 Straight Screw Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: If water leaks from the straight screw plug or the plug corrodes, replace it.
REMOVE 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.
  
  Fig 75: Locating No.2 Straight Screw Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 76: Identifying Intake Valve Guide Bush
  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.
  
  Fig 77: Removing Exhaust Valve Guide Bush Using SST And Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
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.
  
  Fig 78: Identifying Carbon From Top Of Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  - Keep the bearing, connecting rod and cap together.
  - Arrange the piston and connecting rod assemblies in the correct order.
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 79: Identifying Bearing Cap Bolts Removing 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 80: Identifying Bearing Cap Bolts Removing Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and lower bearings.
  
  Fig 81: Identifying Bearing Caps And Lower Bearings
  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.
REMOVE CRANKSHAFT BEARING
HINT:

Arrange the removed parts in the correct order.
REMOVE CRANKSHAFT THRUST WASHER SET
1. Remove the upper bearings and upper thrust washers from the cylinder block.
  
  Fig 82: Identifying Upper Bearings And Upper Thrust Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON RING SET
1. Using a piston ring expander, remove the 2 compression rings.
2. Using a piston ring expander, remove the oil ring rail.
3. Remove the oil ring expander by hand.
  
  Fig 83: Identifying Piston Ring Set Using Piston Ring Expander
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Arrange the removed parts in the correct order.
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 84: Removing Snap Rings From Piston Using Screwdriver
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Gradually heat the piston to approximately 80°C (176°F).
    
    Fig 85: 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 86: Taping Out Piston Pin Using Brass Bar And Plastic Hammer
    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 87: 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 88: Cleaning Piston Ring Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using solvent and a brush, thoroughly clean the piston.
  
  Fig 89: Cleaning Piston
  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 oil nozzles.
2. Check the 3 oil nozzles for damage or clogging.
  
  Fig 90: Identifying Bolt And Oil Nozzle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONNECTING ROD SMALL END BUSH
1. Using SST and press, press out the bush.
  
  Fig 91: Pressing Rod Small End Bushing Using SST And Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09222-30010