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Cylinder Block: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. INSPECT CONNECTING ROD THRUST CLEARANCE  (See INSPECTION )
  2. INSPECT CONNECTING ROD OIL CLEARANCE  (See INSPECTION )
  3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD 
    1. Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly.

      HINT:

      The matchmarks on the connecting rods and caps are provided for ensuring the correct reassembly.

      Fig 1: Aligning Matchmarks Between Connecting Rods And Caps
      G04974284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 12 mm socket wrench, uniformly loosen and remove the 2 bolts.
    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.

      HINT:

      Keep the lower bearing inserted in the connecting rod cap.

    4. 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.
      Fig 2: Identifying Connecting Rods Caps Bolts
      G04974285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE CONNECTING ROD BEARING 
    1. Remove the connecting rod bearings.

      HINT:

      Arrange the removed parts in the correct order.

  5. REMOVE PISTON RING SET 
    1. Using a piston ring expander, remove the 2 compression rings.
    2. Remove the oil ring rail and oil ring expander by hand.

      HINT:

      Arrange the removed parts in the correct order.

      Fig 3: Removing Piston Ring Set
      G04974286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE PISTON PIN HOLE SNAP RING 
    1. Using a screwdriver, pry out the 2 snap rings.
    Fig 4: Prying Out Snap Rings
    G04974287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE PISTON 
    1. Gradually heat the piston to between 80 and 90°C (176 and 194°F).
      Fig 5: Heating Piston To Between 80 And 90°C
      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, pin, rings, connecting rods and bearings in the correct order.
  8. INSPECT CRANKSHAFT THRUST CLEARANCE  (See INSPECTION )
    Fig 6: Tapping Out Piston Pin
    G04974289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE CRANKSHAFT 
    1. Uniformly loosen and remove the 10 main bearing cap bolts in the sequence shown in the illustration.
      Fig 7: Locating Main Bearing Cap Bolts
      G04974290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using 2 removed main bearing cap bolts, remove the 5 main bearing caps and 5 lower bearings.
      NOTE: Insert the bolts into one of the caps. Ease the cap out by gently pulling up and applying force toward the front and back side of the cylinder block, as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block.
      Fig 8: Removing Main Bearing Cap Bolts
      G05238465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • Keep each lower bearing and main bearing cap as a set.
      • Arrange the sets of the main bearing caps and lower bearings in the correct order.
    3. Lift out the crankshaft.
  10. REMOVE UPPER CRANKSHAFT THRUST WASHER 
    1. Remove the upper crankshaft thrust washers from the cylinder block.
    Fig 9: Identifying Oil Groove
    G04974350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE CRANKSHAFT BEARING 
    1. Remove the 5 crankshaft bearings from the cylinder block.

      HINT:

      Arrange the removed parts in the correct order.

      Fig 10: Identifying Crankshaft Bearings
      G05387227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 2 CRANKSHAFT BEARING 
    1. Remove the 5 No. 2 crankshaft bearings from the 5 main bearing caps.

      HINT:

      Arrange the removed parts in the correct order.

      Fig 11: Identifying No. 2 Crankshaft Bearings
      G06008597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon wrench, remove the bolts and oil nozzles.
      Fig 12: Locating Oil Nozzles With Bolts
      G04974295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE STUD BOLT 
  15. REMOVE RING PIN 
  16. REMOVE STRAIGHT PIN 
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