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Cylinder Block: Disassembly

  1. M/T: Remove Flywheel. 
  2. A/T: Remove Drive Plate. 
  3. Install Engine To Engine Stand For Disassembly. 
  4. Remove Timing Chain And Sprockets.  . See REMOVAL  under TIMING CHAIN
  5. Remove Cylinder Head.  See  24 in REMOVAL under CYLINDER HEAD.
  6. Remove Engine Wire. 
  7. Remove Oil Dipstick And Guide. 
    1. Remove the 2 bolts and oil dipstick and guide.
    2. Remove the O-ring from the dipstick.
      Fig 1: Locating Oil Dipstick Guide Mounting Bolts
      G01082541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Remove The 2 Nuts, Bolt And Water Bypass Pipe. 
  9. Remove Thermostat. 
  10. Remove Knock Sensor. 
  11. Remove Engine Coolant Drain Union. 
  12. Remove  Oil Pump 
  13. Remove  Oil Filter 
  14. Using A 12-mm Hexagon Wrench, Remove The Oil Filter Union. 
    Fig 2: Locating Oil Filter Union Bolt
    G01082542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Remove Oil Pan. 
    1. Remove the 14 bolts and 2 nuts.
      Fig 3: Locating Oil Pan Bolts & Nuts
      G01082543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. CAUTION:
      • Be careful not to the damage the oil pan contact surface of the bearing cap subassembly.
      • Be careful not to damage the oil pan flange.
      Fig 4: Using Oil Pan Removal SST
      G01082544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the blade of SST between the bearing cap subassembly and oil pan, and cut off applied sealer and remove the oil pan. SST 09032-00100  .
  16. Remove The 2 Nuts, Bolt, Oil Strainer And Gasket. 
    Fig 5: Locating Oil Strainer Mounting Bolts & Nuts
    G01082545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. Using A Dial Indicator, Measure The Thrust Clearance While Moving The Connecting Rod Back And Forth. 
    1. Standard thrust clearance: 0.160 - 0.342 mm (0.0063 - 0.0135 in.)  .
    2. Maximum thrust clearance: 0.342 mm (0.0135 in.)  .

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

      Connecting rod thickness: 19.788 - 19.840 mm (0.0779 - 0.0781 in.)  .

      Fig 6: Measure Connecting Rod Thrust Clearance
      G01082546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. 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 7: Locating Connecting Rod Cap Bolts
      G01082547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. NOTE: Keep the lower bearing inserted with the connecting rod cap.
      Fig 8: Removing Connecting Rod Cap
      G01082548Courtesy 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.
      Fig 9: Inspecting Crank Pin & Bearing
      G01082549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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: Applying Plastigage To Crank Pin
      G01082550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the connecting rod cap with the 2 bolts. See step  12- 14 under REASSEMBLY.
      NOTE: Do not turn the crankshaft.
    8. Remove the 2 bolts, connecting rod cap and lower bearing (See steps ( b) and ( c )).
      Fig 11: Installing Connecting Rod Cap Bolts
      G01082551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Measure the Plastigage at its widest point.
      Fig 12: Measuring Plastiguage
      G01082552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Standard oil clearance: 0.028 - 0.060 mm (0.0011 - 0.0024 in.)  .
      2. Maximum oil clearance: 0.08 mm (0.0031 in.)  .
        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.

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

      Fig 13: Standard bearing center wall thickness Chart
      G01082553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 14: Locating Bearing & Connecting Rod Marks
      G01082554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Completely remove the Plastigage.
  19. Remove Piston And Connecting Rod Assembles. 
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
      2. NOTE:
      • Keep the bearings, connecting rod and cap together.
      • Arrange the piston and connecting rod assemblies in the correct order.
      Fig 15: Ridge Reaming Cylinders
      G01082555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
  20. Remove Bearing Cap Subassembly And Crankshaft Rear Oil Seal, And Check Oil Clearance. 
    1. Remove the 10 hexagon head bearing cap subassembly bolts.
    2. Uniformly loosen and remove the 10 bearing cap subassembly bolts, in several passes, in the sequence shown.
      Fig 16: Identifying Bolt Removal Sequence
      G01082556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. CAUTION: Be careful not to damage the contact surfaces of the cylinder block and bearing cap subassembly.

      Keep the lower bearing and bearing cap subassembly together.

      Fig 17: Locating Prying Points
      G01082557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, remove the bearing cap subassembly by prying the portions between the cylinder block and bearing cap subassembly. Remove the 5 lower main bearings.
    4. Remove the crankshaft rear oil seal.
      5. NOTE: Keep the upper bearings together with the cylinder block.
    5. Lift out the crankshaft.
    6. Clean each main journal and bearing.
    7. 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 18: Inspecting main Journals & Bearings
      G01082558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Place the crankshaft on the cylinder block.
    9. Lay a strip of Plastigage across each journal.
      Fig 19: Applying Plastiguage To Journals
      G01082559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      10. NOTE: Do not turn the crankshaft.
    10. Install the bearing cap subassembly. See  8 in REASSEMBLY.
    11. Remove the bearing cap subassembly (See steps ( a) to ( e)).
      Fig 20: Identifying Bearing Cap Tightening Sequence
      G01082560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Measure the Plastigage at its widest point.
      Fig 21: measuring main Journal Plastiguage
      G01082561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      1. Standard oil clearance: 0.015 - 0.032 mm (0.0006 - 0.0013 in.)  .
      2. Maximum oil clearance: 0.050 mm (0.0020 in.)  .
        NOTE:

        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.

        Fig 22: Bearing Number Sizing Chart
        G01082562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 23: Locating Jornal Bearing Sizeing Marks
      G01082563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      EXAMPLE: Cylinder block "4" (A)

      + Crankshaft "3" (B)

      = Total number 7 (Use bearing "3")

      Fig 24: Reference Chart
      G01082564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Completely remove the Plastigage.
  21. Check Crankshaft Thrust Clearance. 

    Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

    Fig 25: Measuring Check Crankshaft Thrust Clearance
    G01082565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Standard thrust clearance: 0.04 - 0.24 mm (0.0016 - 0.0094 in.)  .
    2. 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: 2.430 - 2.480 mm (0.0957 - 0.0976 in.)  .

  22. 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.
  23. 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 26: Inspecting For Piston & Pin Slap
    G01082566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. Remove Piston Rings. 
    1. Using a piston ring expander, remove the 2 compression rings.
      Fig 27: Removing Piston Rings
      G01082567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. NOTE: Arrange the piston rings in the correct order only.
    2. Remove the 2 side rails and oil ring by hand.
  25. Disconnect Connecting Rod From Piston. 
    1. Using a small screwdriver, pry out the 2 snap rings.
      Fig 28: Removing Piston Pin Snap Ring
      G01082568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Gradually heat the piston to 80 - 90°C (176 - 194°F).
      Fig 29: Heating Pistons
      G01082569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. NOTE:
      • The piston and pin are a matched set.
      • Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
      Fig 30: Removing Piston Pin
      G01082570Courtesy 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.
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