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Home >> Lexus >> 2003 >> GS 300 >> Repair and Diagnosis >> Engine Performance >> Adjustment >> Engine Mechanical (2JZ-GE) >> Cylinder Block >> Disassembly

Cylinder Block: Disassembly

  1. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY 
  2. REMOVE GENERATOR 

    Remove the bolt, nut, pipe bracket and generator.

  3. REMOVE TIMING BELT AND PULLEYS (See  REMOVAL  ) 
  4. REMOVE NO. 2 WATER BYPASS PIPE WITH HOSE 

    Remove the bolt, 2 nuts, No. 2 water bypass pipe and gasket.

  5. REMOVE WATER PUMP 

    Remove the 6 bolts, water pump and O-ring.

  6. REMOVE CYLINDER HEAD (See  REMOVAL  ) 
  7. REMOVE OIL PRESSURE SWITCH AND KNOCK SENSORS  .

    For Oil Pressure Switch (See step 3 under INSPECTION ).

    For Knock Sensors (See REMOVAL & INSTALLATION (GS300 & IS300) ).

    Using SST, remove the switch and sensors.

    SST 09816-30010

  8. REMOVE OIL FILTER AND BRACKET ASSEMBLY 
    1. Remove the union bolt and oil filter bracket.
    2. Remove the gasket from the union bolt.
    3. Remove the O-ring from the oil filter bracket.
  9. REMOVE NO. 1 OIL PIPE 

    Remove the union bolt, No. 1 oil pipe and 2 gaskets.

  10. REMOVE FUEL INLET PIPE 

    Remove the 2 bolts and fuel inlet pipe.

  11. REMOVE LH ENGINE MOUNTING BRACKET AND INSULATOR ASSEMBLY 

    Remove the 4 bolts and mounting bracket.

  12. REMOVE RH ENGINE MOUNTING BRACKET AND INSULATOR ASSEMBLY 

    Remove the 4 bolts and mounting bracket.

  13. REMOVE OIL PUMP (See  REMOVAL  ) 
  14. REMOVE REAR OIL SEAL RETAINER 
    1. Remove the 6 bolts of the retainer.
    2. Remove the oil seal retainer by prying the area between the oil seal retainer and main bearing cap with a screwdriver.
      Fig 1: Removing Rear Oil Seal Retainer
      G02943669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. CHECK CONNECTING ROD THRUST CLEARANCE 

    Using a dial indicator, measure the thrust clearance while moving the connecting rods back and forth.

    Standard thrust clearance: 

    0.250 - 0.402 mm (0.0098 - 0.0158 in.) 

    Maximum thrust clearance: 

    0.50 mm (0.0197 in.) 

    If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.

    Fig 2: Measuring Connecting Rod Thrust Clearance
    G02943670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Connecting rod thickness: 

    25.898 - 25.950 mm (1.0196 - 1.0217 in.) 

  16. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE 
    1. Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
    2. Remove the connecting rod cap bolts.
    3. Using the 2 removed connecting rod bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
      Fig 3: Identifying Connecting Rod And Cap Matchmarks
      G02943671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 4: Removing Connecting Rod Cap And Lower Bearing
      G02943672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Keep the lower bearing inserted with the connecting rod cap.

    4. Clean the crank pin and bearings.
    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.

    6. Lay a strip of Plastigage across the crank pin.
      Fig 5: Laying Plastigage Strip Across Crankpin
      G02943673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the connecting rod cap with the 2 bolts.

      (See REASSEMBLY )

      Torque: 

      1st 30 N.m (300 kgf.cm, 22 ft.lbf) 

      2nd Turn extra 90° 

      NOTE: Do not turn the crankshaft.
      Fig 6: Installing Connecting Rod Cap
      G02943674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 2 bolts, connecting rod cap and lower bearing. (See procedure (b) and (c) above)
    9. Measure the Plastigage at its widest point.
      Fig 7: Measuring Plastigage At Widest Point
      G02943675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard oil clearance: 

      STANDARD OIL CLEARANCE REFERENCE

      STD 0.023 - 0.041 mm (0.0009 - 0.0016 in.)
      U/S 0.25 0.028 - 0.066 mm (0.0011 - 0.0026 in.)

      Maximum oil clearance: 

      MAXIMUM OIL CLEARANCE REFERENCE

      STD 0.07 mm (0.0027 in.)
      U/S 0.25 0.08 mm (0.0031 in.)

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

      HINT:

      If using a standard bearing, replace 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 connecting rod cap and crankshaft, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

      Fig 8: Marked Number Reference Chart
      G02943676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Marked Number / EXAMPLE: Connecting rod cap "3" + Crankshaft "1"

      = Total number 4 (Use bearing "4")

      Reference 

      Connecting rod big end inside diameter: 

      CONNECTING ROD BIG END INSIDE DIAMETER REFERENCE

      Mark "1" 55.025 - 55.031 mm (2.1663 - 2.1666 in.)
      Mark "2" 55.031 - 55.037 mm (2.1666 - 2.1668 in.)
      Mark "3" 55.037 - 55.043 mm (2.1668 - 2.1670 in.)
      Fig 9: Identifying Marked Number
      G02943677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Crankshaft crank pin diameter: 

      CRANKSHAFT CRANK PIN DIAMETER REFERENCE

      Mark "0" 51.994 - 52.000 mm (2.0470 - 2.0472 in.)
      Mark "1" 51.988 - 51.994 mm (2.0468 - 2.0470 in.)
      Mark "2" 51.982 - 51.988 mm (2.0465 - 2.0468 in.)

      Standard sized bearing center wall thickness: 

      STANDARD SIZED BEARING CENTER WALL THICKNESS REFERENCE

      Mark "1" 1.498 - 1.501 mm (0.0590 - 0.0591 in.)
      Mark "2" 1.501 - 1.504 mm (0.0591 - 0.0592 in.)
      Mark "3" 1.504 - 1.507 mm (0.0592 - 0.0593 in.)
      Mark "4" 1.507 - 1.510 mm (0.0593 - 0.0594 in.)
      Mark "5" 1.510 - 1.513 mm (0.0594 - 0.0596 in.)
    10. Completely remove the Plastigage.
  17. 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.
      • Keep the bearings, connecting rod and cap together.
      • Arrange the piston and connecting rod assemblies in correct order.
        Fig 10: Removing Carbon Ridge From Cylinder Top
        G02943678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. 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: 

    0.020 - 0.220 mm (0.0008 - 0.0087 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.

    Fig 11: Measuring Crankshaft Thrust Clearance While Prying Crankshaft Back And Forth
    G02943679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Thrust washer thickness: 

    1.940 - 1.990 mm (0.0764 - 0.0783 in.) 

  19. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE 
    1. Uniformly loosen and remove the 14 main bearing cap bolts, in several passes, in the sequence shown.
      Fig 12: Loosening Sequence Of Main Bearing Cap Bolts
      G02943680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the main bearing caps, lower bearings and lower thrust washers (No. 4 main bearing cap only).
      Fig 13: Removing Main Bearing Cap Bolts (No. 4 Main Bearing Cap Only)
      G02943681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • Keep the lower bearing and main bearing cap together.
      • Arrange the main bearing caps and lower thrust washers in correct order.
    3. Lift out the crankshaft.

      HINT:

      Keep the upper bearing and upper thrust washers together with the cylinder block.

    4. Clean each main journal and bearing.
    5. Check each main journal and bearing for pitting and scratches.

      If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.

    6. Place the crankshaft on the cylinder block.
    7. Lay a strip of Plastigage across each journal.
      8. Fig 14: Laying Plastigage Strip Across Each Journal
      G02943682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the main bearing caps. (See REASSEMBLY )

      Torque: 

      1st 45 N.m (450 kgf.cm, 33 ft.lbf) 

      2nd Turn extra 90° 

      NOTE: Do not turn the crankshaft.
    9. Remove the main bearing caps.

      (See procedures (a) and (b) above)

    10. Measure the Plastigage at its widest point.
      Fig 15: Measuring Plastigage At Widest Point
      G02943683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard clearance: 

      STANDARD CLEARANCE REFERENCE

      STD 0.026 - 0.040 mm (0.0010 - 0.0016 in.)
      U/S 0.25 0.025 - 0.061 mm (0.0010 - 0.0024 in.)

      Maximum clearance: 

      MAXIMUM CLEARANCE REFERENCE

      STD 0.06 mm (0.0024 in.)
      U/S 0.25 0.08 mm (0.0031 in.)

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

      HINT:

      If using a standard bearing, replace 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 Fig 17 below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

      Fig 16: Identifying Marked Numbers On Cylinder Block & Crankshaft
      G02943685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 17: Marked Numbers On Cylinder Block & Crankshaft Chart
      G02943684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Marked Numbers / EXAMPLE: Cylinder block "3" (A)

      + Crankshaft "4" (B)

      = Total number 7 (Use bearing "3")

      Standard sized bearing selection chart: 

      Fig 18: Standard Sized Bearing Selection Chart
      G02943686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Sized Bearing Selection / EXAMPLE: Cylinder block "3" Crankshaft "4" = Use bearing "3"

      Reference 

      Cylinder block main journal bore diameter (A): 

      CYLINDER BLOCK MAIN JOURNAL BORE DIAMETER (A) REFERENCE

      Mark "0" 66.020 - 66.022 mm (2.59922 - 2.59929 in.)
      Mark "1" 66.022 - 66.024 mm (2.59929 - 2.59936 in.)
      Mark "2" 66.024 - 66.026 mm (2.59936 - 2.59944 in.)
      Mark "3" 66.026 - 66.028 mm (2.59944 - 2.59952 in.)
      Mark "4" 66.028 - 66.030 mm (2.59952 - 2.59960 in.)
      Mark "5" 66.030 - 66.032 mm (2.59960 - 2.59968 in.)
      Mark "6" 66.032 - 66.034 mm (2.59968 - 2.59976 in.)
      Mark "7" 66.034 - 66.036 mm (2.59976 - 2.59984 in.)

      Crankshaft main journal diameter (B): 

      CRANKSHAFT MAIN JOURNAL DIAMETER (B) REFERENCE

      Mark "0" 61.998 - 62.000 mm (2.44086 - 2.44094 in.)
      Mark "1" 61.996 - 61.998 mm (2.44078 - 2.44086 in.)
      Mark "2" 61.994 - 61.996 mm (2.44070 - 2.44078 in.)
      Mark "3" 61.992 - 61.994 mm (2.44063 - 2.44070 in.)
      Mark "4" 61.990 - 61.992 mm (2.44055 - 2.44063 in.)
      Mark "5" 61.988 - 61.990 mm (2.44047 - 2.44055 in.)
      Mark "6" 61.986 - 61.988 mm (2.44039 - 2.44047 in.)
      Mark "7" 61.984 - 61.986 mm (2.44031 - 2.44039 in.)

      Standard bearing center wall thickness: 

      STANDARD BEARING CENTER WALL THICKNESS REFERENCE

      Mark "1" 1.994 - 1.997 mm (0.0785 - 0.0786 in.)
      Mark "2" 1.997 - 2.000 mm (0.0786 - 0.0787 in.)
      Mark "3" 2.000 - 2.003 mm (0.0787 - 0.0789 in.)
      Mark "4" 2.003 - 2.006 mm (0.0789 - 0.0790 in.)
      Mark "5" 2.006 - 2.009 mm (0.0790 - 0.0791 in.)
    11. Completely remove the Plastigage.
  20. REMOVE CRANKSHAFT 
    1. Lift out the crankshaft
    2. Remove the upper bearings and upper thrust washers from the cylinder block.

      HINT:

      Arrange the main bearing caps, bearings and thrust washers in the correct order.

      Fig 19: Removing Crankshaft From Block
      G02943687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. 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 20: Checking Fit Between Piston And Piston Pin
    G02943688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE PISTON RINGS 
    1. Using a piston ring expander, remove the 2 compression rings.
    2. Remove the 2 side rails and oil ring expander by hand.

      HINT:

      Arrange the piston rings in correct order only.

      Fig 21: Removing Piston Rings
      G02943689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT CONNECTING ROD FROM PISTON 
    1. Using a small screwdriver, remove the 2 snap rings.
    2. Gradually heat the piston to about 80°C (176°F).
      Fig 22: Removing Snap Ring
      G02943690Courtesy 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 23: Tapping Out Piston Pin From Piston To Remove Connecting Rod
        G02943691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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