Engine Unit: Disassembly

HINT:

Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
Replace all gaskets, O-rings and oil seals with new parts.

REMOVE TIMING BELT
1. Remove the timing belt (see REMOVAL ).
REMOVE CYLINDER HEAD
1. Remove the cylinder head (see REMOVAL ).
REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
1. Using a 10 mm hexagon wrench, remove the bolt, idler and plate washer.
  
  Fig 1: Removing No. 1 Timing Belt Idler Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 TIMING BELT IDLER SUB-ASSEMBLY
1. Remove the bolt and idler.
  
  Fig 2: Removing No. 2 Timing Belt Idler Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT TIMING PULLEY
1. Using SST, remove the timing pulley.
  SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010)
  
  NOTE: Do not turn the timing pulley.
Fig 3: Removing Crankshaft Timing Pulley
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER PUMP ASSEMBLY (See REMOVAL )
REMOVE NO. 2 OIL PAN SUB-ASSEMBLY (See REMOVAL )
REMOVE OIL PAN BAFFLE PLATE (See REMOVAL )
REMOVE NO. 1 OIL PAN SUB-ASSEMBLY (See REMOVAL )
REMOVE OIL STRAINER SUB-ASSEMBLY (See REMOVAL )
REMOVE OIL PUMP ASSEMBLY (See REMOVAL )
REMOVE REAR OIL SEAL RETAINER
1. Remove the 7 bolts.
2. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and crankshaft bearing cap.
3. Remove the O-ring.
Fig 4: Removing Rear Oil Seal Retainer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Remove the RH and LH drain unions.
INSPECT CONNECTING ROD THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
  1. Standard thrust clearance: 0.160 to 0.290 mm (0.0063 to 0.0114 in.)
  2. Maximum thrust clearance: 0.35 mm (0.0138 in.)
  If the thrust clearance is greater than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
  
  Standard connecting rod thickness: 22.880 to 22.920 mm (0.9008 to 0.9024 in.)
  
  Fig 5: Inspecting Connecting Rod Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE

Check the matchmarks on the connecting rod and cap to ensure correct reassembly.

Fig 6: Checking Matchmarks On Connecting Rod & Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the 2 connecting rod cap bolts.

Fig 7: Removing Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using the removed connecting rod cap bolts, remove the connection rod cap and lower bearing by wiggling the connecting rod cap right and left.
HINT:

Keep the lower bearing inserted with the connecting rod cap.
Clean the crank pin and bearing.
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.
Lay a strip of Plastigage across the crank pin.

Fig 8: Laying Strip Of Plastigage Across Crank Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the connecting rod cap with the 2 bolts.
Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)

NOTE: Do not turn the crankshaft.

If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.

Fig 9: Installing Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Mark the front of the connecting cap bolt with paint.
Retighten the cap bolts 90° as shown in Fig 10.

Fig 10: Retightening Cap Bolts An Additional 90°
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check that the painted mark is now at a 90° angle to the front.
Remove the 2 bolts, connecting rod cap and lower bearing.

Measure the Plastigage at its widest point.

Standard oil clearance: 0.021 to 0.047 mm (0.0008 to 0.0019 in.)
Maximum oil clearance: 0.059 mm (0.0023 in.)

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

Fig 11: Measuring Plastigage At Widest Point

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

If replacing a standard bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the connecting rod cap and crankshaft, and then select the bearing with the same number as the total. There are 6 sizes of standard bearings, marked 2, 3, 4, 5, 6 and 7.

Fig 12: Selecting Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard Bearings

BEARINGS REFERENCE (1 OF 2)

Item	Number Mark
Connecting rod	1		2	1	2	3
Crankshaft	1	2	1	3	2	1
Use bearing	2	3		4

Standard Bearings

BEARINGS REFERENCE (2 OF 2)

Item	Number Mark
Connecting rod	2	3	4	3	4
Crankshaft	3	2	1	3	2	3
Use bearing	5			6		7

EXAMPLE: Connecting rod cap "3" + Crankshaft "1" = "4" (Use bearing "4")

Standard connecting rod big end inside diameter

CONNECTING ROD BIG END INSIDE DIAMETER SPECIFIED CONDITION

Number Mark	Specified Condition
Mark 1	55.000 to less than 55.006 mm (2.1654 to less than 2.1656 in.)
Mark 2	55.006 to less than 55.012 mm (2.1656 to less than 2.1658 in.)
Mark 3	55.012 to less than 55.018 mm (2.1658 to less than 2.1661 in.)
Mark 4	55.018 to less than 55.024 mm (2.1661 to less than 2.1663 in.)

Standard crankshaft crank pin diameter

CRANKSHAFT CRANK PIN DIAMETER SPECIFIED CONDITION

Number Mark	Specified Condition
Mark 1	51.994 to less than 52.000 mm (2.0470 to less than 2.0472 in.)
Mark 2	51.988 to less than 51.994 mm (2.0468 to less than 2.0470 in.)
Mark 3	51.982 to less than 51.988 mm (2.0465 to less than 2.0468 in.)

Standard sized bearing center wall thickness

BEARING THICKNESS SPECIFIED CONDITION

Number Mark	Specified Condition
Mark 2	1.487 to less than 1.490 mm (0.0585 to less than 0.0587 in.)
Mark 3	1.490 to less than 1.493 mm (0.0587 to less than 0.0588 in.)
Mark 4	1.493 to less than 1.496 mm (0.0588 to less than 0.0589 in.)
Mark 5	1.496 to less than 1.499 mm (0.0589 to less than 0.0590 in.)
Mark 6	1.499 to less than 1.502 mm (0.0590 to less than 0.0591 in.)
Mark 7	1.502 to less than 1.505 mm (0.0591 to less than 0.0593 in.)

Completely remove the Plastigage.

REMOVE PISTON AND CONNECTING ROD
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
  HINT:
  - Keep the bearings, connecting rod and cap together.
  - Be sure to arrange the removed piston and connecting rod assemblies in such a way that they can be reinstalled exactly as before.
  Fig 13: Removing Piston & Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
  1. Standard thrust clearance: 0.020 to 0.220 mm (0.0008 to 0.0087 in.)
  2. 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.
  
  Standard thrust washer thickness: 2.440 to 2.490 mm (0.0961 to 0.0980 in.)
  
  Fig 14: Inspecting Crankshaft Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE

Uniformly loosen and remove the 10 crankshaft bearing cap bolts in the sequence shown in Fig 15.

Fig 15: Removing Main Bearing Caps Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using 2 screwdrivers, pry out the crankshaft bearing cap, and remove the 5 crankshaft bearing caps, 5 lower bearings and 2 lower thrust washers (No. 3 crankshaft bearing cap only).
NOTE: Be careful not to damage the cylinder block.

HINT:
- Keep the lower bearing and crankshaft bearing cap together.
- Be sure to arrange the bearing caps and lower thrust washers in such a way that they can be reinstalled exactly as before.
  
  Fig 16: Prying Out Crankshaft Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Lift out the crankshaft.
Remove the 2 upper thrust washers.
HINT:
- Be sure to arrange the removed upper thrust washers in such a way that they can be reinstalled exactly as before.
- Keep the upper bearings together with the cylinder block.
Clean each crankshaft journal and bearing.
Check each crankshaft journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
Place the crankshaft on the cylinder block.
Lay a strip of Plastigage across each journal.

Fig 17: Laying Strip Of Plastigage Across Each Journal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the 5 crankshaft bearing caps in their proper locations.
HINT:

If any one of the main bearing cap bolts is broken or deformed, replace it.

Fig 18: Installing Crankshaft Bearing Caps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts.
Install and uniformly tighten the 10 crankshaft bearing cap bolts in several steps, in the order shown in Fig 19.
Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)

NOTE: Do not turn the crankshaft.

If any one of the crankshaft bearing cap bolts does not meet the torque specification, replace the crankshaft bearing cap bolt.

Fig 19: Installing Crankshaft Bearing Cap Bolts In Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Mark the front of the crankshaft bearing cap bolts with paint.
Retighten the crankshaft bearing cap bolts by 90° in the order shown in Fig 19 .

Fig 20: Retightening Crankshaft Bearing Cap Bolts An Additional 90°
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check that the painted mark is now at a 90° angle to the front.
Remove the crankshaft bearing caps.

Measure the Plastigage at its widest point.

Standard clearance

STANDARD CLEARANCE

Number Mark	Specified Condition
No. 1 and No. 5	0.028 to 0.046 mm (0.0011 to 0.0018 in.)
Others	0.040 to 0.058 mm (0.0016 to 0.0023 in.)

Maximum clearance

MAXIMUM CLEARANCE

Number Mark	Specified Condition
No. 1 and No. 5	0.065 mm (0.0026 in.)
Others	0.065 mm (0.0026 in.)

Fig 21: Measuring Plastigage Widest Point

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

HINT:

If replacing a standard bearing, replace it with one that has 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, and then refer to the tables below for the appropriate bearing number. There are 5 sizes of standard bearings. For No. 1 and No. 5 position bearings, use bearings marked 3, 4, 5, 6 and 7. For other position bearings, use bearings marked 1, 2, 3, 4 and 5.

A = Cylinder block

B = Crankshaft

No. 1 and No. 5

NO. 1 AND NO. 5

(A) + (B)	Use bearing
0 to 5	3
6 to 11	4
12 to 17	5
18 to 23	6
24 to 28	7

EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "5")

Others

BEARINGS REFERENCE

(A) + (B)	Use bearing
0 to 5	1
6 to 11	2
12 to 17	3
18 to 23	4
24 to 28	5

Fig 22: Identifying Bearing Number Mark

EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "3")

Standard cylinder block crankshaft journal bore diameter (A)

CYLINDER BLOCK CRANKSHAFT JOURNAL BORE DIAMETER SPECIFIED CONDITION

Number Mark	Specified Condition
Mark 00	72.000 mm (2.8347 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.)

Standard crankshaft journal diameter (B)

CRANKSHAFT JOURNAL DIAMETER SPECIFIED CONDITION

Number Mark	Specified Condition
Mark 00	67.000 mm (2.6378 in.)
Mark 01	66.999 mm (2.6378 in.)
Mark 02	66.998 mm (2.6377 in.)
Mark 03	66.997 mm (2.6377 in.)
Mark 04	66.996 mm (2.6376 in.)
Mark 05	66.995 mm (2.6376 in.)
Mark 06	66.994 mm (2.6376 in.)
Mark 07	66.993 mm (2.6375 in.)
Mark 08	66.992 mm (2.6375 in.)
Mark 09	66.991 mm (2.6374 in.)
Mark 10	66.990 mm (2.6374 in.)
Mark 11	66.989 mm (2.6374 in.)
Mark 12	66.988 mm (2.6373 in.)

Standard bearing center wall thickness: No. 1 and No. 5

BEARING THICKNESS SPECIFIED CONDITION

Number Mark	Specified Condition
Mark 3	2.487 to less than 2.490 mm (0.0979 to less than 0.0980 in.)
Mark 4	2.490 to less than 2.493 mm (0.0980 to less than 0.0982 in.)
Mark 5	2.493 to less than 2.496 mm (0.0982 to less than 0.0983 in.)
Mark 6	2.496 to less than 2.499 mm (0.0983 to less than 0.0984 in.)
Mark 7	2.499 to less than 2.502 mm (0.0984 to less than 0.0985 in.)

Others

BEARING THICKNESS SPECIFIED CONDITION

Number Mark	Specified Condition
Mark 1	2.481 to less than 2.484 mm (0.0977 to less than 0.0978 in.)
Mark 2	2.484 to less than 2.487 mm (0.0978 to less than 0.0979 in.)
Mark 3	2.487 to less than 2.490 mm (0.0979 to less than 0.0980 in.)
Mark 4	2.490 to less than 2.493 mm (0.0980 to less than 0.0982 in.)
Mark 5	2.493 to less than 2.496 mm (0.0982 to less than 0.0983 in.)

Remove the 5 upper crankshaft bearings from the cylinder block.
HINT:

Be sure to arrange the bearing caps, bearings and thrust washers in such a way that they can be reinstalled exactly as before.

REMOVE PISTON SUB-ASSEMBLY WITH PIN
1. Check the piston and piston pin.
  1. Try to move the piston back and forth on the piston pin.
    If any movement is felt, replace the piston and pin with a new piston and pin set.
    
    Fig 23: Checking Piston & Piston Pin
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a piston ring expander, remove the No. 1 and No. 2 piston rings.
  HINT:
  
  Be sure to arrange the removed piston rings in such a way that they can be reinstalled exactly as before.
  
  Fig 24: Removing No. 1 & 2 Piston Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the oil ring (2 side rails and expander) by hand.
4. Using a small screwdriver, pry out the 2 snap rings.
  
  Fig 25: Prying Out Snap Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Gradually heat the piston to approximately 60°C (140°F).
  
  Fig 26: Heating Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a plastic-faced hammer and brass bar, lightly tap out the piston and pin. Then remove the connecting rod.
  HINT:
  - The piston and pin are a matched set.
  - Be sure to arrange the removed pistons, pins, rings, connecting rods and bearings in such a way that the parts can be reinstalled exactly as before.
  Fig 27: Tapping Out Piston & Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002