Cylinder Block: Disassembly

WARNING: This page is about a different car, the 2004 Toyota MR2, 2003 Toyota MR2, and 2002 Toyota MR2. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
REMOVE CYLINDER HEAD . See REMOVAL .
REMOVE WATER BYPASS PIPE
Remove the 2 nuts, bolts, water bypass pipe and gasket.

Fig 1: Removing Water Bypass Pipe
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE THERMOSTAT . See REMOVAL .
REMOVE KNOCK SENSOR
REMOVE ENGINE COOLANT DRAIN UNION
REMOVE OIL PUMP . See REMOVAL .
REMOVE OIL FILTER . See REPLACEMENT .
REMOVE OIL FILTER UNION
Using a 12 mm hexagon wrench, remove the oil filter union.

Fig 2: Identifying Oil Filter Union
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PAN
1. Remove the 14 bolts and 2 nuts.
  
  Fig 3: Locating Oil Pan Fasteners
  Courtesy 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
  
  Fig 4: Cutting Old Sealer To Remove Oil Pan
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - 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.
REMOVE OIL STRAINER
Remove the 2 nuts, bolt, oil strainer and gasket.

Fig 5: Removing Oil Strainer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

Fig 6: Measuring Connecting Rod Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Standard thrust clearance:
  1. 0.160 - 0.342 mm (0.0063 - 0.0135 in.)
2. Maximum thrust clearance:
  1. 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:
1. 19.788 - 19.840 mm (0.7791 - 0.7811 in.)
REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE
1. Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.
2. Remove the 2 connecting rod cap bolts.
  
  Fig 7: Confirming Connecting Rod Match Mark Alignment
  Courtesy 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.
  
  Fig 8: Using Bolts To Remove Connecting Rod Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Keep the lower bearing inserted with the connecting rod cap.
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 on the crank pin.
  
  Fig 9: Laying Plastigage On Crank Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the connecting rod cap with the 2 bolts. See step 13 under REASSEMBLY.
  NOTE: Do not turn the crankshaft.
8. Remove the 2 bolts, connecting rod cap and lower bearing. See procedure steps b and c above).
  
  Fig 10: Tightening Connecting Rod Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Measure the Plastigage at its widest point.
  
  Fig 11: Using Plastigage To Measure Oil Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Standard oil clearance:
    1. 0.028 - 0.060 mm (0.0011 - 0.0024 in.)
  2. Maximum oil clearance:
    1. 0.08 mm (0.0031 in.)
  If the oil clearance is greater than maximum, replace the bearings. If necessary, 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 12: Locating Bearing Size Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard bearing center wall thickness:
  
  Fig 13: Specifying Bearing Center Wall Thickness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Completely remove the Plastigage.
REMOVE PISTON AND CONNECTING ROD ASSEMBLIES
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
  
  Fig 14: Using Ridge Reamer To Clean Carbon From Top Of Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
  NOTE:
  - Keep the bearings, connecting rod and cap together.
  - Arrange the piston and connecting rod assemblies in the correct order.
REMOVE BEARING CAP SUBASSEMBLY AND CRANKSHAFT REAR OIL SEAL, AND CHECK OIL CLEARANCE
1. Remove the 10 hexagon head bearing cap bolts.
2. Uniformly loosen and remove the 10 bearing cap bolts in several passes, in the sequence shown.
  
  Fig 15: Removing Bearing Cap Bolts In Sequence
  Courtesy 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.
  
  Fig 16: Removing Bearing Cap Subassembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the contact surfaces of the cylinder block and bearing cap subassembly.
  
  NOTE: Keep the lower bearing and bearing cap subassembly together.
4. Remove the crankshaft rear oil seal.
5. Lift out the crankshaft.
  NOTE: Keep the upper bearings together with the cylinder block.
6. Clean each main journal and bearing.
7. Check each main journal, bearing for pitting and scratches.
  If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
8. Place the crankshaft on the cylinder block.
9. Lay a strip of Plastigage across each journal.
  
  Fig 17: Laying Plastigage On Bearing Journal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Install the bearing cap subassembly. See step 7 under REASSEMBLY.
  
  Fig 18: Tightening Bearing Cap Subassembly Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not turn the crankshaft.
11. Remove the bearing cap subassembly. See procedures a to d above.
12. Measure the Plastigage at its widest point.
  
  Fig 19: Measuring Standard Oil Clearance Using Plastigage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Standard oil clearance:
    1. 0.015 - 0.032 mm (0.0006 - 0.0013 in.)
  2. Maximum oil clearance:
    1. 0.050 mm (0.0020 in.)
  If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.
13. 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 20: Locating Bearing Size Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 21: Example Of How To Determine Replacement Bearing Size
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  EXAMPLE: Cylinder block "4" (A) + Crankshaft "3" (B) = Total number 7 (Use bearing "3")
  
  Standard bearings selection chart
  
  Fig 22: Determining Replacement Bearing Size
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  EXAMPLE: Cylinder block "4", Crank shaft "3", Use bearing "3"
  
  Reference
  
  Fig 23: Identifying Bearing Size Based On Reference Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Completely remove the Plastigage.
CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

Fig 24: Measuring Crankshaft Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Standard thrust clearance:
  1. 0.04 - 0.24 mm (0.0016 - 0.0094 in.)
2. Maximum thrust clearance:
  1. 0.30 mm (0.0118 in.)
  If the thrust clearance is greater than maximum, replace the thrust washers as a set.
3. Thrust washer thickness:
  1. 2.430 - 2.480 mm (0.0957 - 0.0976 in.)
REMOVE CRANKSHAFT
1. Lift out the crankshaft.
2. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block.
  HINT:
  
  Arrange the main bearings and thrust washers in the correct order.
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 25: Checking Fit Between Piston & Piston Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON RINGS
1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the 2 side rails and oil ring by hand.
  NOTE: Arrange the piston rings in the correct order only.
DISCONNECT CONNECTING ROD FROM PISTON
1. Using a small screwdriver, pry out the 2 snap rings.
  
  Fig 27: Prying Out Snap Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Gradually heat the piston to 80 - 90°C (176 - 194°F).
  
  Fig 28: Heating Pistons To Prepare For Piston Pin Removal
  Courtesy 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.
  
  Fig 29: Removing Piston Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - The piston and pin are a matched set.
  - Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.