Cylinder Block: Disassembly

Remove the bolt, nut, pipe bracket and generator.

Remove the bolt, 2 nuts, water bypass pipe and gasket.

Remove the 6 bolts, water pump and O-ring.

1. Remove the union bolt and oil filter bracket.
2. Remove the gasket from the union bolt.
3. Remove the O-ring from the oil filter bracket.

Remove the union bolt, oil pipe and 2 gaskets.

Remove the 2 bolts and fuel inlet pipe.

Remove the 4 bolts and mounting bracket.

Remove the 4 bolts and mounting bracket.

1. Remove the 6 bolts of the retainer.
2. Remove the oil seal retainer by prying the area between the oil seal retainer and main bearing cap with a screwdriver.

Fig 1: Removing Rear Oil Seal Retainer

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

1. Standard thrust clearance: 0.250 - 0.402 mm (0.0098 - 0.0158 in.) 
2. Maximum thrust clearance: 0.50 mm (0.0197 in.) 

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

Fig 2: Checking Connecting Rod Thrust Clearance

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1. Connecting rod thickness: 25.898 - 25.950 mm (1.0196 - 1.0217 in.) 

1. Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
2. Remove the connecting rod cap bolts.
   Fig 3: Removing Connecting Rod Cap Bolts

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3. Using the 2 removed connecting rod bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
   Fig 4: Removing Connecting Rod Cap

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   HINT:

   Keep the lower bearing inserted with the connecting rod cap.

4. Clean the crank pin and bearings.
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 across the crank pin.
   Fig 5: Laying Strip Of Plastigage Across Crank Pin

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7. Install the connecting rod cap with the 2 bolts (See REASSEMBLY  ).
   Fig 6: Installing Connecting Rod Cap

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   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.
   Fig 7: Measuring Plastigage At Widest Point

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   Standard oil clearance: 

   Fig 8: Standard Oil Clearance Chart

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   Maximum oil clearance: 

   Fig 9: Maximum Oil Clearance Chart

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

   HINT:

   If using a standard bearing, replace 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 connecting rod cap and crankshaft, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

   Fig 10: Identifying Connecting Rod Bearing Number Marks

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   Fig 11: Connecting Rod Bearing Number Marks Chart

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   EXAMPLE:

   Connecting rod cap "3" + Crankshaft "1"

   = Total number 4 (Use bearing "4")

   Reference 

   Connecting rod big end inside diameter: 

   Fig 12: Connecting Rod Big End Inside Diameter Chart

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   Crankshaft crank pin diameter: 

   Fig 13: Crankshaft Crank Pin Diameter Chart

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   Standard sized bearing center wall thickness: 

   Fig 14: Standard Sized Bearing Center Wall Thickness Chart

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10. Completely remove the Plastigage.

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.
   • Keep the bearings, connecting rod and cap together.
   • Arrange the piston and connecting rod assemblies in correct order.
   Fig 15: Removing Piston And Connecting Rod Assemblies

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

1. Standard thrust clearance: 0.020 - 0.220 mm (0.0008 - 0.0087 in.) 
2. Maximum thrust clearance: 0.30 mm (0.0118 in.) 

Fig 16: Measuring Thrust Clearance Prying Crankshaft With Screwdriver

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

1. Thrust washer thickness: 1.940 - 1.990 mm (0.0764 - 0.0783 in.) 

1. Uniformly loosen and remove the 14 main bearing cap bolts, in several passes, in the sequence shown in Fig 17.
   Fig 17: Removing Bearing Cap Bolts In Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the main bearing caps, lower bearings and lower thrust washers (No.4 main bearing cap only).

   HINT:

   • Keep the lower bearing and main bearing cap together.
   • Arrange the main bearing caps and lower thrust washers in correct order.
3. Lift out the crankshaft.
   Fig 18: Removing Main Bearing Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   Keep the upper bearing and upper thrust washers together with the cylinder block.

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 bearings. 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 19: Laying Strip Of Plastigage Across Each Journal

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8. Install the main bearing caps (See REASSEMBLY  ).
   NOTE: Do not turn the crankshaft.
9. Remove the main bearing caps (See procedures  a and above).
10. Measure the Plastigage at its widest point.
    Fig 20: Measuring Plastigage At Widest Point

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    Standard clearance: 

    Fig 21: Standard Clearance Chart

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    Maximum clearance: 

    Fig 22: Maximum Clearance Chart

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

    HINT:

    If using a standard bearing, replace 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 refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

    Fig 23: Identifying Crankshaft Bearings Number Marks

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    Fig 24: Cylinder Block And Crankshaft Number Mark Chart

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    EXAMPLE:

    Cylinder block "3" (A) + Crankshaft "4" (B)

    = Total number 7 (Use bearing "3"

    Standard sized bearing selection chart: 

    Fig 25: Standard Sized Bearing Selection Chart

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Reference 

    Cylinder block main journal bore diameter (A): 

    Fig 26: Cylinder Block Main Journal Bore Diameter Chart

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Crankshaft main journal diameter (B): 

    Fig 27: Crankshaft Main Journal Diameter Chart

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    Standard bearing center wall thickness: 

    Fig 28: Standard Bearing Center Wall Thickness Chart

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Completely remove the Plastigage.

1. Lift out the crankshaft
   Fig 29: Lifting Out Crankshaft

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2. Remove the upper bearings and upper thrust washers from the cylinder block.

HINT:

Arrange the main bearing caps, bearings and thrust washers in the correct order.

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 30: Checking Fit Between Piston And Piston Pin

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1. Using a piston ring expander, remove the 2 compression rings.
   Fig 31: Removing Compression Rings

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2. Remove the 2 side rails and oil ring expander by hand.

HINT:

Arrange the piston rings in correct order only.

1. Using a small screwdriver, remove the 2 snap rings.
   Fig 32: Removing Snap Rings Using Screwdriver

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2. Gradually heat the piston to about 80°C (176°F).
3. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.
Fig 33: Tapping Out Piston And Removing Connecting Rod
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HINT:

• The piston and pin are a matched set.
• Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.