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Cylinder Block: Disassembly

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  1. INSTALL ENGINE TO ENGINE STAND 
  2. REMOVE TIMING BELT AND PULLEYS (See  REMOVAL   ) 
  3. REMOVE CYLINDER HEAD (See  REMOVAL   ) 
  4. REMOVE WATER BYPASS PIPE 
    1. Disconnect the wire clamp (for knock sensor 1, 2) from the bracket of the water bypass pipe.
    2. Remove the bolt.
    3. Pull out the water bypass pipe from the water pump.
    4. Remove the O-ring from the water bypass pipe.
    Fig 1: Removing Water Bypass Pipe
    G02987073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE STARTER (See  REMOVAL  ) 
  6. REMOVE KNOCK SENSORS (See  INSPECTION  ) 
  7. DISCONNECT ENGINE WIRE FROM LH SIDE OF CYLINDER BLOCK 
    1. Remove the 2 bolts and the engine wire cover from the LH side of the cylinder block.
      2. Fig 2: Removing Engine Wire Cover
      G02987074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, disconnect the bracket on the engine wire from the cylinder block.
  8. DISCONNECT ENGINE WIRE FROM RH SIDE OF CYLINDER BLOCK 

    Remove the 2 bolts, and disconnect the 2 brackets on the engine wire from the cylinder block.

    Fig 3: Removing Engine Brackets
    G02987075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE OIL COOLER PIPE BRACKET FOR A/T 

    Remove the bolt and bracket.

  10. REMOVE ENGINE MOUNTING BRACKETS 

    Remove the 4 bolts and the mounting bracket. Remove the 2 mounting brackets

  11. REMOVE WATER PUMP (See  REMOVAL  ) 
  12. REMOVE NO. 2 OIL PAN (See  REMOVAL  ) 
  13. REMOVE OIL PAN BAFFLE PLATE 
  14. REMOVE NO. 1 OIL PAN (See  REMOVAL  ) 
  15. REMOVE OIL STRAINER 
  16. REMOVE OIL PUMP (See  REMOVAL  ) 
  17. REMOVE ENGINE COOLANT DRAIN UNIONS 

    Remove the 2 drain unions.

  18. REMOVE REAR OIL SEAL RETAINER 
    1. Remove the 7 bolts.
    2. Using a screwdriver, ply off the oil seal retainer and the main bearing cap with a screwdriver.
    3. Remove the O-ring.
    Fig 4: Removing Rear Oil Seal Retainer
    G02987076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. CHECK CONNECTING ROD THRUST CLEARANCE 

    Using a dial indicator, measure the thrust clearance while moving the connecting rod back an a forth.

    Standard thrust clearance: 

    0.160 - 0.290 mm (0.0063 - 0.0138 in.) 

    Maximum thrust clearance: 0.35 mm (0.0138 in.) 

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

    Connecting rod thickness: 

    22.880 - 22.920 mm (0.9008 - 0.9024 in.) 

    Fig 5: Measuring Connecting Rod Thrust Clearance
    G02987077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. 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 2 connecting rod cap bolts.
      Fig 6: Removing Connecting Rod Cap Bolts
      G02987078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and the lower bearing by wiggling the connecting rod cap right and left.

      HINT:

      Keep the lower bearing inserted with the connecting rod cap.

      Fig 7: Removing Connecting Rod Caps
      G02987079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Clean the crank pin and the bearing.
    5. Check the crank pin and the bearing for pitting and scratches.

      If the crank pin or the bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

    6. Lay a strip of plastigage across the crank pin.
      Fig 8: Laying A Strip Of Plastigage Across Crank Pin
      G02987080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the connecting rod cap with the 2 bolts.

      (See REASSEMBLY  )

      NOTE: Do not turn the crankshaft.
      Fig 9: Installing Connecting Rod Cap Bolts
      G02987081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 2 bolts, the connecting rod cap and the lower bearing. (See procedure  b and  c)
    9. Measure the plastigage at its widest point.

      Standard oil clearance: 

      0.027 - 0.053 mm (0.0011 - 0.0021 in.) 

      Maximum oil clearance: 0.065 mm (0.0026 in.) 

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

      Fig 10: Measuring Plastigage At Widest Point
      G02987082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      If using a standard bearing, replace it with the one having the same number. If the number of the bearing cannot be determined, sum up the numbers imprinted on the connecting rod cap and the crankshaft, then select the one with the same number as the total. There are 6 sizes of standard bearings, marked "2", "3", "4", "5", "6" and "7".

      Fig 11: Bearing Number Identification Chart
      G02987083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      EXAMPLE:

      Connecting rod cap "3" + Crankshaft "1"

      = Total number 4 (Use bearing "4")

      Fig 12: Locating Connecting Rod Bearing Identification Numbers
      G02987084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Reference 

      Connecting rod big end inside diameter: 

      CONNECTING ROD BIG REFERENCE

      Mark "1" 55.000 - 55.006 mm (2.1654 - 2.1656 in.)
      Mark "2" 55.006 - 55.012 mm (2.1656 - 2.1658 in.)
      Mark "3" 55.012 - 55.018 mm (2.1658 - 2.1661 in.)
      Mark "4" 55.018 - 55.024 mm (2.1661 - 2.1663 in.)

      Crankshaft crank pin diameter: 

      CRANKSHAFT CRANK PIN REFERENCE

      Mark "1" 51.994 - 52.000 mm (2.0470 - 2.0472 in.)
      Mark "2" 51.988 - 51.994 mm (2.0468 - 2.0470 in.)
      Mark "3" 51.982 - 51.988 mm (2.0465 - 2.0468 in.)

      Standard sized bearing center wall thickness: 

      BEARING CENTER WALL THICKNESS SPECIFICATION

      Mark "2" 1.484 - 1.487 mm (0.0584 - 0.0585 in.)
      Mark "3" 1.487 - 1.490 mm (0.0585 - 0.0587 in.)
      Mark "4" 1.490 - 1.493 mm (0.0587 - 0.0588 in.)
      Mark "5" 1.493 - 1.496 mm (0.0588 - 0.0589 in.)
      Mark "6" 1.496 - 1.499 mm (0.0589 - 0.0590 in.)
      Mark "7" 1.499 - 1.502 mm (0.0590 - 0.0591 in.)
    10. Completely remove the plastigage.
  21. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES 
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
      2. Fig 13: Using Ridge Reamer
      G02987085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

    HINT:

    • Keep the bearings, the connecting rod and the cap together.
    • Arrange the piston and connecting rod assemblies in correct order.
  22. 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 the maximum, replace the thrust washers as a set.

    Thrust washer thickness: 

    2.440 - 2.490 mm (0.0961 - 0.0980 in.) 

    Fig 14: Checking Crankshaft Thrust Clearance
    G02987086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE 
    1. Evenly loosen and remove the 10 main bearing cap bolts a little at a time for several times, in the sequence shown.
      Fig 15: Main Bearing Cap Bolt Removal Sequence
      G02987087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using 2 screwdrivers, pry out the main bearing cap, and remove the 5 main bearing caps, the 5 lower bearings and the 2 lower thrust washers (No. 3 main bearing cap only).
      NOTE: Be careful not to damage the cylinder block.

      HINT:

      • Keep the lower bearing and main bearing cap together.
      • Arrange the main bearing caps and lower thrust washers in correct order.
      Fig 16: Removing Main Bearing Caps
      G02987088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Lift out the crankshaft.

      HINT:

      Keep the upper bearings and the 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, replace the crankshaft.

    6. Place the crankshaft on the cylinder block.
    7. Lay a strip of plastigage across each journal.
      Fig 17: Placing Crankshaft On Crankshaft
      G02987089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the main bearing caps.

      (See REASSEMBLY  )

      NOTE: Do not turn the crankshaft.
      Fig 18: Installing Main Bearing Cap Bolts
      G02987090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the main bearing caps.

      (See procedure  a and  b)

    10. Measure the plastigage at its widest point.

      Standard clearance: 

      0.040 - 0.058 mm (0.0016 - 0.0023 in.) 

      Maximum clearance: 0.070 mm (0.0028 in.) 

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

      Fig 19: Measuring Plastigage Widest Point
      G02987091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      If using a standard bearing, replace it with the one having the same number. If the number of the bearing cannot be determined, sum up the numbers imprinted on the cylinder block and the crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of the standard bearings. For No. 1 and No. 5 position bearings, use bearings marked "3", "4", "5", "6" and "7". For others position bearings, use bearings marked "1", "2", "3", "4" and "5".

      Fig 20: Locating Crankshaft Bearing Numbers
      G02987093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      No. 1, No. 5: 

      Fig 21: Bearing Number Application Chart (No. 1 & No. 5)
      G02987092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      EXAMPLE:

      Cylinder block "08" + Crankshaft "06"

      = Total number 14 (Use bearing "5")

      Others: 

      Fig 22: Bearing Number Application Chart (Other Bearings)
      G02987094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      EXAMPLE:

      Cylinder block "08" + Crankshaft "06"

      = Total number 14 (Use bearing "3")

      Reference 

      Cylinder block main journal bore diameter (A): 

      CYLINDER BLOCK MAIN JOURNAL BORE DIAMETER "A"

      Mark "00" 72.000 mm (2.8346 in.)
      Mark "01" 72.001 mm (2.8347 in.)
      Mark "02" 72.002 mm (2.8347 in.)
      Mark "03" 72.003 mm (2.8348 in.)
      Mark "04" 72.004 mm (2.8348 in.)
      Mark "05" 72.005 mm (2.8348 in.)
      Mark "06" 72.006 mm (2.8349 in.)
      Mark "07" 72.007 mm (2.8349 in.)
      Mark "08" 72.008 mm (2.8350 in.)
      Mark "09" 72.009 mm (2.8350 in.)
      Mark "10" 72.010 mm (2.8350 in.)
      Mark "11" 72.011 mm (2.8351 in.)
      Mark "12" 72.012 mm (2.8351 in.)
      Mark "13" 72.013 mm (2.8352 in.)
      Mark "14" 72.014 mm (2.8352 in.)
      Mark "15" 72.015 mm (2.8352 in.)
      Mark "16" 72.016 mm (2.8353 in.)

      Crankshaft main journal diameter (B): 

      CYLINDER BLOCK MAIN JOURNAL BORE DIAMETER "B"

      Mark "00" 7.000 mm (2.6378 in.)
      Mark "01" 6.999 mm (2.6378 in.)
      Mark "02" 6.998 mm (2.6377 in.)
      Mark "03" 6.997 mm (2.6377 in.)
      Mark "04" 6.996 mm (2.6376 in.)
      Mark "05" 6.995 mm (2.6376 in.)
      Mark "06" 6.994 mm (2.6376 in.)
      Mark "07" 6.993 mm (2.6375 in.)
      Mark "08" 6.992 mm (2.6375 in.)
      Mark "09" 6.991 mm (2.6374 in.)
      Mark "10" 6.990 mm (2.6374 in.)
      Mark "11" 6.989 mm (2.6374 in.)
      Mark "12" 6.988 mm (2.6373 in.)

      Standard bearing center wall thickness: 

      No. 1 and No. 5 

      STANDARD BEARING CENTER WALL THICKNESS (No. 1 & No. 5)

      Mark "3" 2.481 - 2.484 mm (0.0977 - 0.0978 in.)
      Mark "4" 2.484 - 2.487 mm (0.0978 - 0.0979 in.)
      Mark "5" 2.487 - 2.490 mm (0.0979 - 0.0980 in.)
      Mark "6" 2.490 - 2.493 mm (0.0980 - 0.0981 in.)
      Mark "7" 2.493 - 2.496 mm (0.0981 - 0.0983 in.)

      Others: 

      STANDARD BEARING CENTER WALL THICKNESS (Other Bearings)

      Mark "1" 2.481 - 2.484 mm (0.0977 - 0.0978 in.)
      Mark "2" 2.484 - 2.487 mm (0.0978 - 0.0979 in.)
      Mark "3" 2.487 - 2.490 mm (0.0979 - 0.0980 in.)
      Mark "4" 2.490 - 2.493 mm (0.0980 - 0.0981 in.)
      Mark "5" 2.493 - 2.496 mm (0.0981 - 0.0983 in.)
    11. Completely remove the Plastigage.
  24. REMOVE CRANKSHAFT 
    1. Lift up the crankshaft.
    2. Remove the 5 upper main bearings and the 2 upper thrust washers from the cylinder block.

    HINT:

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

  25. 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 23: Checking Fit Between Piston And Piston Pin
    G02987095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE PISTON RINGS 
    1. Using a piston ring expander, remove the 2 compression rings.
    2. Remove the 2 side rails and the oil ring by hand.

    HINT:

    Arrange the piston rings in correct order installation.

    Fig 24: Removing Piston Rings
    G02987096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT CONNECTING ROD FROM PISTON 
    1. Using a small screwdriver, pry out the 2 snap rings.
      Fig 25: Removing Snap Rings
      G02987097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Gradually heat the piston to approx. 60°C (140°F).
      Fig 26: Heating Pistons
      G02987098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic-faced hammer and a brass bar, lightly tap out the piston pin and remove the connecting rod.

    HINT:

    • The piston and the pin are a matched set.
    • Arrange the pistons, the pins, rings, the connecting rods and the bearings in correct order for installation.
    Fig 27: Taping Out Piston Pin
    G02987099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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