Cylinder Block: Disassembly

WARNING: This page is about a different car, the 2003 Lexus RX 300. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE DRIVE PLATE
Remove the 8 bolts, rear plate, drive plate and front spacer.
INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
REMOVE TIMING BELT AND PULLEYS (See REMOVAL )
REMOVE CYLINDER HEAD (See REMOVAL )

Fig 1: Removing Timing Belt And Pulleys
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR
DISCONNECT OIL PRESSURE SWITCH CONNECTOR
REMOVE GENERATOR, ADJUSTING BAR AND BRACKET ASSEMBLY
1. Disconnect the 2 wire clamps from the wire brackets.
2. Remove the 3 nuts, the generator, adjusting bar and bracket assembly.
REMOVE OIL PRESSURE SWITCH (See OIL AND FILTER )

Fig 2: Removing Oil Pressure Switch
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REMOVE A/C COMPRESSOR HOUSING BRACKET
Remove the 2 bolts and compressor housing bracket.

Fig 3: Removing A/C Compressor Housing Bracket
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REMOVE NO. 2 IDLER PULLEY BRACKET
Remove the 2 bolts and idler pulley bracket.

Fig 4: Removing Bolts And Idler Pulley Bracket
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REMOVE KNOCK SENSORS
1. Disconnect the 2 knock sensor connectors.
2. Using SST, remove the 2 knock sensors.
  - SST 09816-30010
  Fig 5: Disconnect Knock Sensor Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER INLET HOUSING
1. Remove the engine wire band.
2. Disconnect the engine wire clamp from the bracket.
3. Disconnect the No. 2 ECT switch connector.
4. Disconnect the engine wire clamp from the water inlet.
5. Remove the 8 bolts, 2 nuts and water inlet housing.
REMOVE WATER PUMP (See WATER PUMP )
REMOVE OIL STRAINER (See OIL PUMP )
REMOVE NO.1 OIL PAN (See OIL PUMP )
REMOVE OIL PUMP (See OIL PUMP )
REMOVE OIL FILTER (See OIL AND FILTER )
REMOVE OIL FILTER UNION
Using a 12 mm hexagon wrench, remove the oil filter union.
REMOVE WATER SEAL PLATE
Remove the 2 nuts and seal plate.
REMOVE ENGINE COOLANT DRAIN UNION(S)

Fig 7: Removing Engine Coolant Drain Union
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2WD: REMOVE CYLINDER BLOCK SIDE COVER
Remove the 3 bolts, 2 nuts, cylinder block side cover and gasket.

Fig 8: Removing Cylinder Block Side Cover
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REMOVE REAR OIL SEAL RETAINER
1. Remove the 6 bolts.
2. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and main bearing cap.
  
  Fig 9: Removing Rear Oil Seal Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
- Standard thrust clearance: 0.15 - 0.30 mm (0.0059 - 0.0118 in.)
- Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
- Connecting rod thickness: 20.80 - 20.85 mm (0.8189 - 0.8209 in.)
Fig 10: Measuring Thrust Clearance While Moving Connecting Rod Back
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE
1. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
2. Remove the 2 connecting rod cap bolts.
  
  Fig 11: Removing Connecting Rod 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 with the connecting rod cap.
  
  Fig 12: Removing Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Clean the crank pin and bearing.
5. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
  
  Fig 13: Cleaning Crank Pin And Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Lay a strip of Plastigage across the crank pin.
  
  Fig 14: Laying A Strip Of Plastigage Across Crank Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the connecting rod cap with the 2 bolts. (See REASSEMBLY )
  - Torque:
  - 1st: 24.5 N.m (250 kgf.cm, 18 ft.lbf)
  - 2nd: Turn extra 90°
  NOTE: Do not turn the crankshaft.
8. Remove the 2 bolts, connecting rod cap and lower bearing. (See procedure (b) and (c) above)
  
  Fig 15: Connecting Rod Cap And Lower Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Measure the Plastigage at its widest point.
  - Standard oil clearance: 0.038 - 0.064 mm (0.0015 - 0.0025 in.)
  - Maximum oil clearance: 0.08 mm (0.0031 in.)
  If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.
  
  Fig 16: Measuring Plastigage At Widest Point
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.
  
  Reference:
  
  Standard bearing center wall thickness:
  
  Fig 17: Identifying Bearing Center Wall Thickness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Completely remove the Plastigage.
  
  Fig 18: Removing Plastigage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON AND CONNECTING ROD ASSEMBLIES
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
  HINT:
  - Keep the bearings, connecting rod and cap together.
  - Arrange the piston and connecting rod assemblies in the correct order.
    
    Fig 19: Removing Piston And Connecting Rod Assemblies
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
- Standard thrust clearance: 0.04 - 0.24 mm (0.0016 - 0.0095 in.)
- Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the thrust washers as a set.
- Thrust washer thickness: 1.930 - 1.980 mm (0.0760 - 0.0780 in.)
Fig 20: Measuring Thrust Clearance While Prying Crankshaft Back
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE
1. Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the several passes, in the sequence shown.
  
  Fig 21: Removing Main Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen and remove the 16 main bearing cap bolts in several passes, in the sequence shown.
  
  Fig 22: Removing Main Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, pry out main bearing caps. Remove the 4 main bearing caps, lower bearings and (No.2 main bearing cap only) 2 lower thrust washers.
  
  Fig 23: Prying Out Main Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Pull up the main bearing cap little by little to the right and the left by turns and pay attention not to damage the joint surface of the cylinder block and the main bearing cap.
  
  HINT:
  - Keep the lower bearing and main bearing cap together.
  - Arrange the main bearing caps and lower thrust washers in correct order.
    
    Fig 24: Pulling Up Main Bearing Cap
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Lift out the crankshaft.
  HINT:
  
  Keep the upper bearings together with the cylinder block.
5. Clean each main journal and bearing.
6. Check each main journal and bearing for pitting and scratches.
  If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
  
  Fig 25: Lifting Out Crankshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Place the crankshaft on the cylinder block.
8. Lay a strip of Plastigage across each journal.
  
  Fig 26: Placing Crankshaft On Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Install the 4 main bearing caps.
  (See REASSEMBLY )
  - Torque:
  - 12 pointed head bolts:
    - 1st: 22 N.m (225 kgf.cm, 16 ft.lbf)
    - 2nd: Turn extra 90°
  - Hexagon head bolts:
    - 27 N.m (275 kgf.cm, 20 ft.lbf)
  NOTE: Do not turn the crankshaft.
  
  Fig 27: Installing Main Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Remove the main bearing caps.
  (See procedures (a) to (c) above)
11. Measure the Plastigage at its widest point.
  - Standard oil clearance:
  - No.1 and No.4 journals:
    - 0.014 - 0.034 mm (0.0006 - 0.0013 in.)
  - No. 2 and No. 3 journals:
    - 0.026 - 0.046 mm (0.0010 - 0.0018 in.)
  - Maximum clearance:
  - No.1 and No.4 journals: 0.05 mm (0.0020 in.)
  - No. 2 and No. 3 journals: 0.06 mm (0.0024 in.)
  Fig 28: Removing Main Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.
  
  HINT:
  
  If using 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, then refer to the table below for the appropriate bearing number. The No.1 and No.4 journal bearings have 5 standard bearing sizes, marked "3", "4", "5", "6" and "7" accordingly. The No. 2 and No. 3 journal bearings have 5 standard bearing sizes, marked "1", "2", "3", "4" and "5" accordingly.
  
  Fig 29: Identifying No.1 And No.4 Journal Bearings Chart
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 30: Identifying Crank Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  EXAMPLE: Cylinder block "06" (A) + Crankshaft "08" (B) = Total number 14 (Use bearing "5")
  
  Fig 31: Identifying No.1 And No.4 Journal Standard Bearings Selection Chart
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  EXAMPLE: Cylinder block "06", Crankshaft "08" = Use bearing "5"
  
  Fig 32: Identifying No. 2 And No. 3 Journal Bearings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  EXAMPLE: Cylinder block "06" (A) + Crankshaft "08" (B) = Total number 14 (Use bearing "3")
  
  Fig 33: Identifying No. 2 And No. 3 Journal Standard Bearings Selection Chart
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  EXAMPLE: Cylinder block "06", Crankshaft "08" = Use bearing "3"
  
  Reference:
  
  Fig 34: Reference Chart
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Completely remove the Plastigage.
REMOVE CRANKSHAFT
1. Lift out the crankshaft.
2. Remove the 4 upper main bearings and 2 upper thrust washers from the cylinder block.
HINT:

Arrange the main bearing caps, bearings and thrust washers in the correct order.
CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.

Fig 35: Checking Fit Between Piston And Piston Pin
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REMOVE PISTON RINGS
1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the 2 side rails and oil ring by hand.
HINT:

Arrange the piston rings in the correct order only.

Fig 36: Removing Side Rails And Oil Ring By Hand
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DISCONNECT CONNECTING ROD FROM PISTON
1. Using a small screwdriver, pry out the 2 snap rings.
  
  Fig 37: Prying Out Snap Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Gradually heat the piston to approx. 60°C (140°F).
  
  Fig 38: Identifying Heat Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic-faced hammer and brass bar, 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 39: Identifying Plastic-Faced Hammer And Brass Bar
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