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Cylinder Block: Disassembly

  1. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY  .
  2. REMOVE TIMING CHAIN  . Refer to REMOVAL .
  3. REMOVE CYLINDER HEAD  . Refer to REMOVAL .
  4. REMOVE ENGINE WIRE  .
  5. REMOVE WATER BYPASS PIPE  .

    Remove the 2 nuts, bolt and water bypass pipe.

    Fig 1: Removing Water Bypass Pipe Nuts And Bolt
    G02810742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE THERMOSTAT  Refer to REMOVAL .
  7. REMOVE KNOCK SENSOR  Refer to REMOVE KNOCK SENSOR .
  8. REMOVE OIL PRESSURE SWITCH  Refer to REMOVE OIL PRESSURE SWITCH .
  9. REMOVE ENGINE COOLANT DRAIN UNION 
  10. REMOVE OIL FILTER  Refer to REMOVE OIL FILTER .
  11. REMOVE OIL FILTER UNION  .

    Using a 12 mm hexagon wrench, remove the oil filter union.

    Fig 2: Removing Oil Filter Union
    G02810743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE OIL PAN NO. 2 
    1. Remove the 9 bolts and 2 nuts.
    2. Insert the blade of SST between the oil pan No. 1 and oil pan No. 2, and cut off applied sealer and remove the oil pan.
      Fig 3: Removing Oil Pan No. 2
      G02810744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09032-00100

      NOTE:
      • Be careful not to the damage the oil pan contact surface of the oil pan No. 1.
      • Be careful not to damage the oil pan No. 2 flange.
  13. REMOVE OIL STRAINER  .

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

    Fig 4: Locating Oil Strainer Nuts And Bolt
    G02810745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE OIL PAN NO. 1 
    1. Uniformly loosen and remove the 13 bolts, in several passes, in the sequence shown.
      Fig 5: Removing Oil Pan No. 1
      G02810746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using screwdriver remove the oil pan No. 1 by prying the portions between the cylinder block and oil pan No. 1.
      Fig 6: Locating Cylinder Block And Oil Pan No. 1 Portions
      G02810747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 O-rings from the cylinder block.
  15. CHECK CONNECTING ROD THRUST CLEARANCE 

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

    Standard thrust clearance: 0.16 - 0.36 mm (0.0063 - 0.0142 in.) 

    Maximum thrust clearance: 0.36 mm (0.0142 in.) 

    Fig 7: Measuring Connecting Rod Thrust Clearance
    G02810748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  16. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE 
    1. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
      Fig 8: Checking Matchmarks On Connecting Rod And Cap
      G02810749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 connecting rod cap bolts.
      3. NOTE: Keep the lower bearing inserted with the connecting rod cap.
      Fig 9: Removing Connecting Rod Cap With Bolts
      G02810750Courtesy 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.
    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.

    6. Lay a strip of Plastigage the crank pin.
      Fig 10: Laying A Plastigage Strip
      G02810751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the connecting rod cap with the 2 bolts. (See REASSEMBLY )

      Torque: 

      1ST 15 N.m (150 kgf.cm, 11 ft.lbf) 

      2ND Turn 90° 

      Fig 11: Installing Connecting Rod Cap Bolts
      G02810752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not turn the crankshaft.
    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.

      Standard oil clearance: 0.016 - 0.040 mm (0.0006 - 0.0016 in.) 

      Maximum oil clearance: 0.06 mm (0.0024 in.) 

      Fig 12: Measuring Plastigage At Its Widest Point
      G02810753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.
      Fig 13: Identifying Marks
      G02810754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Reference 

      STANDARD BEARING CENTER WALL THICKNESS

      Mark mm (in.)
      "1" 1.488 - 1.492 (0.0586 - 0.0587)
      "2" 1.492 - 1.496 (0.0587 - 0.0589)
      "3" 1.496 - 1.500 (0.0589 - 0.0591)
    10. Completely remove the plastigage.
  17. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES 
    NOTE:
    • Keep the bearings, connecting rod and cap together.
    • Arrange the piston and connecting rod assemblies in the correct order.
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
      Fig 14: Removing All Carbon From Top Of Cylinder
      G02810755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
  18. CHECK CRANKSHAFT THRUST CLEARANCE 

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

    Standard thrust clearance: 0.09 - 0.19 mm (0.0035 - 0.0075 in.) 

    Maximum thrust clearance: 0.3 mm (0.012 in.) 

    Fig 15: Measuring Thrust Clearance
    G02810756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    If the thrust clearance is greater than maximum, replace the thrust washer as a set.

    Thrust washer thickness: 2.430 - 2.480 mm (0.09567 - 0.09764 in.) 

  19. REMOVE BEARING CAPS AND CHECK OIL CLEARANCE 
    1. Uniformly loosen and remove the 10 bearing cap bolts in several passes in the sequence shown.
      Fig 16: Identifying Bearing Cap Bolts
      G02810757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. NOTE: Keep the lower bearing inserted with the bearing cap.
      Fig 17: Removing Bearing Cap Using 2 Removed Bearing Cap Bolts
      G02810758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using the 2 removed bearing cap bolts, remove the bearing cap and lower bearing by wiggling the bearing cap right and left.
      3. NOTE: Keep the upper bearings and thrust washers together with the cylinder block.
    3. Lift out the crankshaft.
    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 bearing. If necessary, grind or replace the crankshaft.

    6. Place the crankshaft on the cylinder block.
    7. Lay a strip of plastigage across each journal.
      Fig 18: Applying A Strip Of Plastigage Across Journal
      G02810759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      8. NOTE: Do not turn the crankshaft.
      If using a standard 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 selecting the bearing with the same number as the total. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.
    8. Install the bearing caps. Refer to INSTALLATION .

      Torque: 1ST 22 N.m (220 kgf.cm, 16 ft.lbf) 

      2ND Turn 90° 

    9. Remove the bearing caps (See procedure (a) and (b) above).
    10. Measure the plastigage at its widest point.

      Standard oil clearance: 0.010 - 0.023 mm (0.0004 - 0.0009 in.) 

      Maximum oil clearance: 0.07 mm (0.0028 in.) 

      Fig 19: Measuring Plastigage At Its Widest Point
      G02810760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      EXAMPLE: Cylinder block "4" (A) + Crankshaft "3" (B) = Total number 7 (Use bearing "3")

      Fig 20: Standard Bearing Number Mark Reference Chart
      G02810761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 21: Identifying Number Marks
      G02810762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 22: Journal Diameter And Bearing Thickness Reference Chart
      G02810763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Completely remove the Plastigage.
  20. REMOVE CRANKSHAFT 
    1. Lift out the crankshaft.
      2. NOTE: Arrange the main bearings and thrust washers in the correct order.
    2. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block.
  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 23: Checking Piston Pin Fit
    G02810764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE PISTON RINGS 
    NOTE: Arrange the piston rings in the correct order only.
    Fig 24: Removing Compression Rings
    G02810765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a piston ring expander, remove the 2 compression rings.
    2. Remove the oil ring by hand.
  23. DISCONNECT CONNECTING ROD FROM PISTON 
    NOTE:
    • The piston and pin are a matched set. 
    • Arrange the pistons, pins, rings, connecting rods and bearings in correct order. 

    Using SST, press out the piston pin from the piston. Remove the piston.

    SST 09221-25026 (09221-00021, 09221-00030, 09221-00190, 09221-00141, 09221-00150)

Fig 25: Disconnecting Connecting Rod From Piston
G02810766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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