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Cylinder Block: Disassembly

  1. REMOVE NO. 1 VENTILATION CASE 
    1. Remove the 6 bolts and 2 nuts.
      Fig 1: Locating Bolts And Nuts
      G05398978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block with a screwdriver as shown the illustration.
      NOTE: Be careful not to damage the contact surfaces of the cylinder block and No. 1 ventilation case.

      HINT:

      Tape the screwdriver tip before use.

      Fig 2: Prying No. 1 Ventilation Case
      G05398979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD 
    1. Using a ridge reamer, remove all carbon from the top of the cylinder.
      Fig 3: Removing Carbon From Top Of Cylinder
      G05398980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that the alignment mark on the connecting rod and cap are aligned to ensure correct reassembly.

      HINT:

      The alignment mark on the connecting rods and caps are provided to ensure correct reassembly.

      Fig 4: Identifying Alignment Mark On Connecting Rod And Cap
      G05398981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, uniformly loosen the 2 bolts.

      SST 09205-16010 

      Fig 5: Loosening Bolts
      G05398982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using the 2 loose 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 in the connecting rod cap.

      Fig 6: Loosening Connecting Rod Cap Bolts
      G05398983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Push the piston, connecting rod assembly 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 assemblies in the correct order.
  3. REMOVE CONNECTING ROD BEARING 
    1. Remove the connecting rod bearings.

      HINT:

      Arrange the removed parts in the correct order.

  4. REMOVE PISTON RING SET 
    1. Using a piston ring expander, remove the 2 compression rings.
      2. Fig 7: Removing Compression Rings
      G05398984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the oil ring rail and oil ring expander by hand.

      HINT:

      Arrange the removed parts in the correct order.

  5. REMOVE PISTON PIN HOLE SNAP RING 
    1. Using a screwdriver, pry out the 2 snap rings.
      Fig 8: Prying Out Snap Rings
      G05398985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE PISTON SUB-ASSEMBLY WITH PIN 
    1. Gradually heat each piston to between 80 and 90°C (176 to 194°F).
      Fig 9: Heating Piston
      G04974288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic 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 10: Tapping Out Piston Pin
        G05398987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE CRANKSHAFT 
    1. Uniformly loosen and remove the 10 main bearing cap bolts in the sequence shown in the illustration.
      Fig 11: Locating Main Bearing Cap Bolts And Loosening Sequence
      G05398988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Use 2 loose main bearing cap bolts to remove the 5 main bearing caps and 5 lower bearings.
      NOTE: Insert the bolts into the caps in turn. Ease the cap out by gently pulling up and applying force toward the front and back sides of the cylinder block, as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block.
      Fig 12: Loosening Main Bearing Cap Bolts
      G05398989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • Keep the lower bearing and main bearing cap together.
      • Arrange the main bearing caps in the correct order.
    3. Lift out the crankshaft.
  8. REMOVE UPPER CRANKSHAFT THRUST WASHER 
    1. Remove the upper crankshaft thrust washers from the cylinder block.
      Fig 13: Locating Upper Crankshaft Thrust Washers
      G05398990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE CRANKSHAFT BEARING 
    1. Remove the 5 upper main bearings from the cylinder block.

      HINT:

      Arrange the bearings in the correct order.

      Fig 14: Locating Upper Main Bearings
      G05398991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 lower main bearings from the 5 main bearing caps.

      HINT:

      Arrange the bearings in the correct order.

      Fig 15: Identifying Lower Main Bearing
      G05398992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a socket hexagon wrench 5, remove the bolts and oil nozzles.
      2. Fig 16: Locating Bolts And Oil Nozzles
      G05398993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. CLEAN CYLINDER BLOCK 
    NOTE: If the cylinder is washed at high temperatures, the cylinder liner will stick out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.
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