Engine Unit: Disassembly

1. Remove the ventilation valve.

Fig 1: Locating Ventilation Valve

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1. Remove the 4 bolts and 4 sensors.

Fig 2: Locating VVT Sensor Bolts

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1. Remove the 4 bolts and 4 oil control valves.

Fig 3: Locating Camshaft Timing Oil Control Valve Bolts

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1. Remove the oil check valve bolt, oil pipe union and oil pipe.
2. Remove the oil control valve filter LH and gaskets.

Fig 4: Locating Oil Check Valve Bolt And Oil Pipe Union

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1. Remove the oil check valve bolt, oil pipe union and oil pipe.
2. Remove the oil control valve filter RH and gaskets.

Fig 5: Locating Oil Check Valve Bolt And Oil Pipe Union

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1. Remove the 2 water drain cocks from the cylinder block.
   Fig 6: Locating Water Drain Cocks

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2. Remove the water drain cock plugs from the water drain cocks.

1. Separate the water bypass hoses.
   Fig 7: Locating Water Bypass Hoses

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2. Remove the 4 bolts, nut and water inlet.
   Fig 8: Locating Water Inlet Bolt And Nut

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3. Remove the 2 O-rings.
   Fig 9: Identifying O-Rings

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4. Remove the 3 water bypass hoses.

Fig 10: Locating Water Bypass Hoses

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1. Remove the 3 nuts and water inlet with thermostat.
2. Remove the gasket from the water inlet.

Fig 11: Locating Water Inlet With Thermostat Nuts

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1. Remove the 2 bolts, 4 nuts and water bypass joint.
   Fig 12: Locating Rear Water Bypass Joint Bolts And Nuts

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2. Remove the 2 gaskets and O-ring.

Fig 13: Locating Gaskets And O-Ring

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1. Using SST, loosen the crankshaft pulley set bolt.

   SST 09213-70011 (09213-70020), 09330-00021 

   Fig 14: Loosening Crankshaft Pulley Set Bolt

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2. Using the pulley set bolt and SST, remove the crankshaft pulley.
   Fig 15: Removing Crankshaft Pulley

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   SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) 

1. Remove the 14 bolts, cylinder head cover and gasket.

   HINT:

   Make sure that the removed parts are returned to the same places they were removed from.

Fig 16: Locating Cylinder Head Cover Bolts

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1. Remove the 12 bolts, cylinder head cover and gasket.

   HINT:

   Make sure that the removed parts are returned to the same places they were removed from.

Fig 17: Locating Cylinder Head Cover Bolts

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1. Remove the 15 bolts and 2 nuts.
   Fig 18: Locating No. 2 Oil Pan Bolts And Nuts

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2. Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

   SST 09032-00100 

   NOTE: Be careful not to damage the contact surfaces of the oil pans.
3. Remove the drain plug and gasket.

Fig 19: Inserting Blade Of SST Between Oil Pans

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1. Remove the 14 bolts and 2 nuts.

   HINT:

   Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

   Fig 20: Locating No. 2 Oil Pan Bolts And Nuts

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2. Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

   SST 09032-00100 

   NOTE: Be careful not to damage the contact surfaces of the oil pans.
3. Remove the drain plug and gasket.

Fig 21: Inserting Blade Of SST Between Oil Pans

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1. Remove the 3 nuts, pipe and gasket.

   HINT:

   Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

Fig 22: Locating Oil Strainer Pipe Nuts

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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 23: Identifying Oil Pan Sub-Assembly Bolts And Nuts

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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 24: Identifying Oil Pan And Cylinder Prying Location

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3. Remove the 2 O-rings.

Fig 25: Locating O-Rings

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1. Remove the 16 bolts and 2 nuts.

   HINT:

   Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

   Fig 26: Identifying Oil Pan Sub-Assembly Nuts And Bolts (For 4WD)

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2. Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.
   NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

   HINT:

   Tape the screwdriver tip before use.

   Fig 27: Identifying Oil Pan And Cylinder Block Prying Location

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3. Remove the 2 O-rings.

Fig 28: Locating O-Rings

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1. Remove the 3 nuts, oil strainer and gasket.

Fig 29: Identifying Oil Strainer Nuts

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1. Remove the bolt, 2 nuts, strainer and gasket.

Fig 30: Locating Oil Strainer Bolt And Nuts

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1. Remove the 8 bolts and baffle plate.

Fig 31: Locating Oil Pan Baffle Plate Bolts

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1. Remove the 6 bolts.
   Fig 32: Locating Engine Rear Oil Seal Retainer Bolts

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2. Using a screwdriver, pry out the oil seal retainer.

   HINT:

   Tape the screwdriver tip before use.

1. Temporarily tighten the pulley set bolt.
   Fig 33: Prying Out Oil Seal Retainer

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2. Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC / compression).
   Fig 34: Setting Timing Mark On Crank Angle Sensor Plate To RH Block Bore Center Line

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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 35: Checking Timing Marks Of Camshaft Timing Gears

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Fig 36: Removing No.1 Chain Tensioner Assembly

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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 hole.
3. Remove the 2 bolts and chain tensioner.

1. Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing gear.
2. Remove the chain from the crankshaft timing gear and place it on the crankshaft.
   Fig 37: Removing Chain Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the camshaft timing gear on the RH bank clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the center banks.
4. Remove the chain.

Fig 38: Identifying Camshaft Timing Gear

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1. Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket and No. 1 idle gear shaft.

Fig 39: Removing Idle Sprocket Assembly

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1. Remove the 2 bolts and vibration damper.

Fig 40: Identifying No.1 Chain Vibration Damper Bolts

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1. Remove the 2 chain vibration dampers.

Fig 41: Locating No.2 Chain Vibration Damper

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1. Remove the crankshaft timing sprocket from the crankshaft.
2. Remove the 2 set keys from the crankshaft.

Fig 42: Removing Crankshaft Timing Sprocket

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1. While raising up the No. 2 chain tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it in place.
   Fig 43: Inserting Pin Into Hole For Fixing No. 2 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 gears.
   NOTE:

   • Be careful not to damage the cylinder head with the wrench.
   • Do not disassemble the camshaft timing gear.
3. Remove the No. 2 chain.

Fig 44: Removing Camshaft Timing Gear

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1. Remove the bolt and chain tensioner.

Fig 45: Locating Chain Tensioner Bolt

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1. Remove the 3 gaskets.
   Fig 46: Locating Camshaft Gaskets (Bank 1)

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2. Make sure that the knock pin of the camshaft is positioned as shown in the illustration.
   Fig 47: Identifying Position Of Camshafts

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3. Uniformly loosen and remove the 9 bearing cap bolts in the sequence shown in the illustration.
   Fig 48: Identifying Removing Sequence Of Bearing Cap Bolts

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4. 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.
5. Remove the 6 bearing caps.
6. Remove the camshaft and No. 2 camshaft.

Fig 49: Identifying Removing Sequence Of Bearing Cap Bolts

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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 50: Identifying Camshaft Housing

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1. While pushing down the chain tensioner, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it in place.
   Fig 51: Inserting Pin Into Hole

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the hexagonal portion of the camshaft with a wrench and remove the 2 bolts and 2 camshaft timing gears.
   NOTE:

   • Be careful not to damage the cylinder head with the wrench.
   • Do not disassemble the camshaft timing gear.
3. Remove the No. 2 chain.

Fig 52: Removing Bolts And Camshaft Timing Gears

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1. Remove the bolt and chain tensioner.

Fig 53: Locating Chain Tensioner Bolt

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1. Remove the 3 gaskets.
   Fig 54: Locating Camshaft (For Bank 2) Gaskets

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2. Make sure that the knock pin of the camshaft is positioned as shown in the illustration.
   Fig 55: Identifying Position Of Camshaft

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3. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
   Fig 56: Identifying Removing Sequence Of Bearing Cap Bolts

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4. Uniformly loosen and remove the 13 bearing cap bolts in the sequence shown in the illustration.
   NOTE: Uniformly loosen the bolts while keeping the camshaft level.
5. Remove the 5 bearing caps.
6. Remove the No. 3 and No. 4 camshafts.

Fig 57: Identifying Removing Sequence Of Bearing Cap Bolts

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Fig 58: Removing Camshaft Housing

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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.

1. Remove the 24 valve rocker arms.

   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 59: Identifying Removing Sequence Of Cylinder Head Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

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

   HINT:

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

2. Remove the cylinder head and gasket.

1. Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.
   Fig 60: Identifying Removing Sequence Of Cylinder Head Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
   NOTE:

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

   HINT:

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

3. Remove the cylinder head and gasket.

Fig 61: Identifying Removing Sequence Of Cylinder Head Bolts

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1. Remove the 2 bolts and outlet pipe.

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

   HINT:

   Arrange the removed parts in the correct order.

Fig 62: Locating Water Outlet Pipe Bolts

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1. Using SST and wooden blocks, compress the compression spring and remove the valve retainer lock.

   SST 09202-70020 (09202-00010) 

2. Remove the retainer, compression spring and valve.

   HINT:

   Arrange the removed parts in the correct order.

Fig 63: Removing Intake Valve Retainer Lock

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1. Using SST and wooden blocks, compress the compression spring and remove the valve retainer lock.

   SST 09202-70020 (09202-00010) 

2. Remove the retainer, compression spring and valve.

   HINT:

   Arrange the removed parts in the correct order.

Fig 64: Removing Exhaust Valve Retainer Lock

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1. Using needle-nose pliers, remove the oil seals.

Fig 65: Removing Valve Stem Oil

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Fig 66: Removing Valve Spring Seat

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1. Using compressed air and a magnetic finger, remove the valve spring seat by blowing air onto it.

1. Using a 10 mm hexagon wrench, remove the 4 screw plugs and 4 gaskets.

Fig 67: Locating Screw Plugs And Gaskets

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1. Using a 14 mm hexagon wrench, remove the 2 screw plugs and 2 gaskets.
   NOTE: If water leaks from the No. 2 screw plug or the plug is corroded, replace it.

Fig 68: Locating Screw Plugs

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1. Remove the bolt and crankshaft position sensor.

Fig 69: Locating Crankshaft Position Sensor Bolt

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1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
   Fig 70: Measuring Thrust Clearance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard thrust clearance: 

   0.15 to 0.40 mm (0.0059 to 0.0157 in.) 

   Maximum thrust clearance: 

   0.50 mm (0.0197 in.) 

   If the thrust clearance is greater than the maximum, replace one or more connecting rods as necessary. If necessary, replace the crankshaft.

1. Check that the front mark on the connecting rod and cap are aligned to ensure the correct reassembly.
2. Remove the 2 connecting rod cap bolts.
   Fig 71: Removing Connecting Cap Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using the 2 removed connecting rod cap 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. Clean the crank pin and bearing.
5. Check the crank pin and bearing for pitting and scratches.
   Fig 72: Removing Connecting Rod Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Lay a strip of Plastigage on the crank pin.
   Fig 73: Laying Strip Of Plastigage On Crank Pin

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7. Check that the front mark of the connecting rod cap is facing forward.
   Fig 74: Checking Front Mark Of Connecting Rod Cap

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8. Install and alternately tighten the bolts of the connecting rod cap in several steps.

   Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

   NOTE: Do not turn the crankshaft.
   Fig 75: Tightening Connecting Rod Cap Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Mark the front side of each connecting cap bolt with paint.
10. Retighten the cap bolts by 90° as shown.
11. Check that the painted marks are now at a 90° angle to the front.
    NOTE: Do not turn the crankshaft.
12. Remove the 2 connecting rod cap bolts.
13. Using the 2 removed connecting rod cap 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.

    Fig 76: Checking Painted Mark On Cap Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Measure the Plastigage at its widest point.

    Standard oil clearance: 

    0.045 to 0.067 mm (0.0018 to 0.0026 in.) 

    Maximum oil clearance: 

    0.070 mm (0.0028 in.) 

    If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

    HINT:

    If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, 3 or 4 mark on its surface.

    Reference: 

    Connecting rod big end inside diameter 

    CONNECTING ROD BIG END INSIDE DIAMETER SPECIFICATION
    
    

    Mark	Thickness
    1	56.000 to 56.006 mm (2.2047 to 2.2050 in.)
    2	56.007 to 56.012 mm (2.2050 to 2.2052 in.)
    3	56.013 to 56.018 mm (2.2052 to 2.2054 in.)
    4	56.019 to 56.024 mm (2.2055 to 2.2057 in.)

    Standard sized bearing center wall thickness 

    BEARING CENTER WALL THICKNESS SPECIFICATION
    
    

    Mark	Thickness
    1	1.481 to 1.484 mm (0.0583 to 0.0584 in.)
    2	1.484 to 1.487 mm (0.0584 to 0.0585 in.)
    3	1.487 to 1.490 mm (0.0585 to 0.0587 in.)
    4	1.490 to 1.493 mm (0.0587 to 0.0588 in.)

    Crankshaft pin diameter: 

    52.992 to 53.000 mm (2.0863 to 2.0866 in.) 

15. Completely remove the Plastigage.

Fig 77: Measuring Plastigage At Its Widest Point

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1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Push the piston, connecting rod 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 in the correct order.

Fig 78: Removing Carbon From Top Of Cylinder

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Arrange the removed parts in the correct order.

1. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

   Standard thrust clearance: 

   0.04 to 0.24 mm (0.0016 to 0.0094 in.) 

   Maximum thrust clearance: 

   0.30 mm (0.0118 in.) 

   If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.

   Standard thrust washer thickness: 

   2.43 to 2.48 mm (0.0957 to 0.0976 in.) 

Fig 79: Measuring Crankshaft Thrust Clearance

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1. Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in several steps, in the sequence shown in the illustration.
   Fig 80: Identifying Removing Sequence Of Main Bearing Cap Bolts

   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 81: Identifying Removing Sequence Of Bearing Cap Bolts

   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:

   • Pry up the main cap little by little to the right and left in turns.
   • Be careful not to damage the joint surface of the cylinder block and main bearing caps.
4. Clean each main journal and bearing.
5. Check each main journal and bearing for pitting and scratches.

   HINT: 

   If the journal or bearing is damaged, replace the bearing. 

6. Place the crankshaft on the cylinder block.
   Fig 82: Prying Out Main Bearing Caps

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Lay a strip of Plastigage across each journal.
8. Examine the front marks and numbers and install the bearing caps on the cylinder block.

   HINT:

   A number is marked on each main bearing cap to indicate the installation position.

9. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
10. Place the crankshaft bearing cap on the cylinder block.
    Fig 83: Laying Strip Of Plastigage Across Journal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Install the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.

    Bolt length: 

    100 to 102 mm (3.94 to 4.02 in.) 

    Fig 84: Inserting Main Bearing Cap

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.
13. Apply a light coat of engine oil on the threads and under the heads of the 8 main bearing cap bolts.
    Fig 85: Tapping Bearing Cap

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Install the 8 main bearing cap bolts to the outside positions.

    Bolt length 

    BOLT LENGTH SPECIFICATION
    
    

    Item	Length
    Bolt A	100 to 102 mm (3.94 to 4.02 in.)
    Except bolt A	10S.5 to 107.5 mm (4.15 to 4.23 in.)

    HINT:

    The main bearing cap bolts are tightened in 2 progressive steps.

    Fig 86: Identifying Main Bearing Cap Bolts Specification

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15. Step 1:
    1. Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.

       Torque: 61 N*m (622 kgf*cm, 45 ft/lbf) 

       HINT:

       If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.

       NOTE: Do not turn the crankshaft.
    Fig 87: Identifying Tightening Sequence Of Main Bearing Cap Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. Step 2:
    1. Mark the front of the bearing cap bolts with paint.
    2. Retighten the bearing cap bolts by 90° in the order shown in  1.
    3. Check that the painted marks are now at a 90° angle to the front.
    Fig 88: Checking Painted Mark On Bearing Cap Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. Install and uniformly tighten the 8 main bearing cap bolts in several steps, in the sequence shown in the illustration.

    Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 

    Bolt length 

    BOLT LENGTH SPECIFICATION
    
    

    Item	Length
    Bolt A	45 mm (1.77 in.)
    Except bolt A	30 mm (1.18 in.)

18. Remove the 24 bolts and bearing cap bolts.
19. Completely remove the Plastigage.
    Fig 89: Identifying Tightening Sequence Of Main Bearing Cap Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft. Refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

    Journal bearing 

    JOURNAL BEARING SPECIFICATION
    
    

    Cylinder Block Number Mark + Crankshaft Number Mark	Used Bearing
    0 - 5	1
    6 - 11	2
    12 - 17	3
    18 - 23	4
    24 - 28	5

    Fig 90: Identifying Bearing Mark On Crankshaft

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    EXAMPLE:

    Cylinder block "11" + Crankshaft "06" = Total

    number 17 (Use bearing "3")

    Standard crankshaft main journal diameter 

    CRANKSHAFT MAIN JOURNAL DIAMETER SPECIFICATION
    
    

    Number Mark	Specified Condition
    Mark 00	60.999 to 61.000 mm (2.4015 to 2.4016 in.)
    Mark 01	60.998 to 60.999 mm (2.4015 to 2.4015 in.)
    Mark 02	60.997 to 60.998 mm (2.4015 to 2.4015 in.)
    Mark 03	60.996 to 60.997 mm (2.4014 to 2.4015 in.)
    Mark 04	60.995 to 60.996 mm (2.4014 to 2.4014 in.)
    Mark 05	60.994 to 60.995 mm (2.4013 to 2.4014 in.)
    Mark 06	60.993 to 60.994 mm (2.4013 to 2.4013 in.)
    Mark 07	60.992 to 60.993 mm (2.4013 to 2.4013 in.)
    Mark 08	60.991 to 60.992 mm (2.4012 to 2.4013 in.)
    Mark 09	60.990 to 60.991 mm (2.4012 to 2.4012 in.)
    Mark 10	60.989 to 60.990 mm (2.4011 to 2.4012 in.)
    Mark 11	60.988 to 60.989 mm (2.4011 to 2.4011 in.)

    Standard upper bearing center wall thickness (No. 1 and No. 4 journal) 

    UPPER BEARING CENTER WALL THICKNESS SPECIFICATION
    
    

    Number Mark	Specified Condition
    Mark 1	2.500 to 2.503 mm (0.0984 to 0.0985 in.)
    Mark 2	2.503 to 2.506 mm (0.0985 to 0.0987 in.)
    Mark 3	2.506 to 2.509 mm (0.0987 to 0.0988 in.)
    Mark 4	2.509 to 2.512 mm (0.0988 to 0.0989 in.)
    Mark 5	2.512 to 2.515 mm (0.0989 to 0.0990 in.)

    Standard upper bearing center wall thickness (No. 2 and No. 3 journal) 

    UPPER BEARING CENTER WALL THICKNESS SPECIFICATION
    
    

    Number Mark	Specified Condition
    Mark 1	2.478 to 2.481 mm (0.0976 to 0.0977 in.)
    Mark 2	2.481 to 2.484 mm (0.0977 to 0.0978 in.)
    Mark 3	2.484 to 2.487 mm (0.0978 to 0.0979 in.)
    Mark 4	2.487 to 2.490 mm (0.0979 to 0.0980 in.)
    Mark 5	2.490 to 2.493 mm (0.0980 to 0.0981 in.)

    Standard lower bearing center wall thickness (No. 1 and No. 4 journal) 

    LOWER BEARING CENTER WALL THICKNESS SPECIFICATION
    
    

    Number Mark	Specified Condition
    Mark 1	2.475 to 2.478 mm (0.0974 to 0.0976 in.)
    Mark 2	2.478 to 2.481 mm (0.0976 to 0.0977 in.)
    Mark 3	2.481 to 2.484 mm (0.0977 to 0.0978 in.)
    Mark 4	2.484 to 2.487 mm (0.0978 to 0.0979 in.)
    Mark 5	2.487 to 2.490 mm (0.0979 to 0.0980 in.)

    Standard lower bearing center wall thickness (No. 2 and No. 3 journal) 

    LOWER BEARING CENTER WALL THICKNESS SPECIFICATION
    
    

    Number Mark	Specified Condition
    Mark 1	2.497 to 2.500 mm (0.0983 to 0.0984 in.)
    Mark 2	2.500 to 2.503 mm (0.0984 to 0.0985 in.)
    Mark 3	2.503 to 2.506 mm (0.0985 to 0.0987 in.)
    Mark 4	2.506 to 2.509 mm (0.0987 to 0.0988 in.)
    Mark 5	2.509 to 2.512 mm (0.0988 to 0.0989 in.)

21. Lift out the crankshaft.
22. Remove the upper bearings and upper thrust washers from the cylinder block.

    HINT:

    Arrange the bearings and thrust washers in the correct order.

1. Remove the 2 water drain cocks from the cylinder block.
2. Remove the water drain cock plugs from the water drain cocks.

Fig 91: Locating Upper Bearings And Upper Thrust Washers

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a 5 mm hexagon wrench, remove the 3 oil nozzles and bolts.
2. Check the oil nozzles for damage or clogging. If necessary, replace the oil nozzle.

HINT:

Arrange the piston rings in the correct order.

Fig 92: Locating Oil Nozzles Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a piston ring expander, remove the 2 compression rings.
2. Using a piston ring expander, remove the 2 oil ring rails.
3. Remove the oil ring expander by hand.

1. Check the fitting condition between the piston and piston pin.
   1. Try to move the piston back and forth on the piston pin.

      HINT:

      If any movement is felt, replace the piston and pin as a set.

   Fig 93: Removing Piston Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the connecting rod from the piston.
   1. Using a screwdriver, pry off the snap rings from the piston.
      Fig 94: Prying Off Snap Rings

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Gradually heat the piston to approximately 80°C (176°F).
      Fig 95: Applying Heat To Piston

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using a brass bar and plastic-faced 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 96: Tapping Out Piston Pin

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Clean piston.
   1. Using a gasket scraper, remove the carbon from the piston top.
      Fig 97: Removing Carbon From Piston Top

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
      Fig 98: Cleaning Piston Ring Grooves

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using solvent and a brush, thoroughly clean the piston.
      NOTE: Do not use a wire brush.

Fig 99: Cleaning Piston

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002