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Cylinder Block: Disassembly

  1. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY 
  2. REMOVE GENERATOR 

    Remove the bolt, nut, pipe bracket and generator.

  3. REMOVE TIMING BELT AND PULLEYS (See  REMOVAL  ) 
  4. REMOVE NO. 2 WATER BYPASS PIPE WITH HOSE 

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

  5. REMOVE WATER PUMP 

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

  6. REMOVE CYLINDER HEAD (See  REMOVAL  ) 
  7. REMOVE OIL PRESSURE SWITCH (See  OIL AND FILTER  ) AND KNOCK SENSORS (See  INSPECTION  ) 
  8. REMOVE OIL FILTER AND BRACKET ASSEMBLY 
    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.
  9. REMOVE NO. 1 OIL PIPE 

    Remove the union bolt, oil pipe and 2 gaskets.

  10. REMOVE FUEL INLET PIPE 

    Remove the 2 bolts and fuel inlet pipe.

  11. REMOVE LH ENGINE MOUNTING BRACKET AND INSULATOR ASSEMBLY 

    Remove the 4 bolts and mounting bracket.

  12. REMOVE RH ENGINE MOUNTING BRACKET AND INSULATOR ASSEMBLY 

    Remove the 4 bolts and mounting bracket.

  13. REMOVE OIL PUMP (See  REMOVAL  ) 
  14. REMOVE REAR OIL SEAL RETAINER 
    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
    G02948498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. CHECK CONNECTING ROD THRUST CLEARANCE 

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

    Standard thrust clearance: 

    0.250-0.402 mm (0.0098-0.0158 in.) 

    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: Measuring Thrust Clearance While Moving Connecting Rods Back And Forth
    G02948499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Connecting rod thickness: 

    25.898-25.950 mm (1.0196-1.0217 in.) 

  16. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE 
    1. Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
      2. Fig 3: Identifying Matchmarks On Connecting Rod And Cap
      G02948500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the connecting rod cap bolts.
    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.

      HINT:

      Keep the lower bearing inserted with the connecting rod cap.

      Fig 4: Removing Connecting Rod Cap And Lower Bearing
      G02948501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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
      G02948502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the connecting rod cap with the 2 bolts (See REASSEMBLY ).
      NOTE: Do not turn the crankshaft.
      Fig 6: Installing Connecting Rod Cap Bolts
      G02948503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 Its Widest Point
      G02948504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard oil clearance: 

      STANDARD OIL CLEARANCE SPECIFICATION

      STD 0.023-0.041 mm (0.0009-0.0016 in.)
      U/S 0.25 0.028-0.066 mm (0.0011-0.0026 in.)

      Maximum oil clearance: 

      MAXIMUM OIL CLEARANCE SPECIFICATION

      STD 0.07 mm (0.0027 in.)
      U/S 0.25 0.08 mm (0.0031 in.)

      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 8: Identifying Marking On Connecting Rod Cap, Bearing And Crankshaft
      G02948505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 9: Connecting Rod Cap, Bearing And Crankshaft Marking Detail Chart
      G02948506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      EXAMPLE:

      Connecting rod cap "3" + Crankshaft "1" = Total number 4 (Use bearing "4")

      Reference 

      Connecting rod big end inside diameter: 

      CONNECTING ROD BIG END INSIDE DIAMETER SPECIFICATION

      Mark "1" 55.025-55.031 mm (2.1663-2.1666 in.)
      Mark "2" 55.031-55.037 mm (2.1666-2.1668 in.)
      Mark "3" 55.037-55.043 mm (2.1668-2.1670 in.)

      Crankshaft crank pin diameter: 

      CRANKSHAFT CRANK PIN DIAMETER SPECIFICATION

      Mark "0" 51.994-52.000 mm (2.0470-2.0472 in.)
      Mark "1" 51.988-51.994 mm (2.0468-2.0470 in.)
      Mark "2" 51.982-51.988 mm (2.0465-2.0468 in.)

      Standard sized bearing center wall thickness: 

      STANDARD SIZED BEARING CENTER WALL THICKNESS SPECIFICATION

      Mark "1" 1.498-1.501 mm (0.0590-0.0591 in.)
      Mark "2" 1.501-1.504 mm (0.0591-0.0592 in.)
      Mark "3" 1.504-1.507 mm (0.0592-0.0593 in.)
      Mark "4" 1.507- 1.510 mm (0.0593-0.0594 in.)
      Mark "5" 1.510- 1.513 mm (0.0594-0.0596 in.)
    10. Completely remove the Plastigage.
  17. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES 
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
      2. Fig 10: Removing All Carbon From Top Of Cylinder
      G02948507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  18. CHECK CRANKSHAFT THRUST CLEARANCE 

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

    Standard thrust clearance: 

    0.020-0.220 mm (0.0008-0.0087 in.) 

    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: 

    1.940-1.990 mm (0.0764-0.0783 in.) 

    Fig 11: Checking Crankshaft Thrust Clearance
    G02948508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE 
    1. Uniformly loosen and remove the 14 main bearing cap bolts, in several passes, in the sequence shown.
      Fig 12: Identifying Removing Sequence Of Main Bearing Cap Bolts
      G02948509Courtesy 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.
      Fig 13: Removing Main Bearing Caps, Lower Bearings And Lower Thrust Washers
      G02948510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Lift out the crankshaft.

      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.
      8. Fig 14: Laying Strip Of Plastigage Across Each Journal
      G02948511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the main bearing caps (See REASSEMBLY ).
      NOTE: Do not turn the crankshaft.
    9. Remove the main bearing caps (See procedures  a and  b above).
    10. Measure the Plastigage at its widest point.
      Fig 15: Measuring Plastigage At Its Widest Point
      G02948512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard clearance: 

      STANDARD CLEARANCE SPECIFICATION

      STD 0.026-0.040 mm (0.0010-0.0016 in.)
      U/S 0.25 0.025-0.061 mm (0.0010-0.0024 in.)

      Maximum clearance: 

      MAXIMUM CLEARANCE SPECIFICATION

      STD 0.06 mm (0.0024 in.)
      U/S 0.25 0.08 mm (0.0031 in.)

      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 Fig 16 for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

      Fig 16: Identifying Marking On Cylinder Block, Bearings And Crankshaft
      G02948513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 17: Cylinder Block, Bearings And Crankshaft Marking Detail Chart
      G02948514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      EXAMPLE:

      Cylinder block "3" (A) + Crankshaft "4" (B) = Total number 7 (Use bearing "3")

      Standard sized bearing selection chart: 

      Fig 18: Standard Sized Bearing Selection Chart
      G02948515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      EXAMPLE:

      Cylinder block "3", Crankshaft "4" = Use bearing "3"

      Reference 

      Cylinder block main journal bore diameter (A): 

      CYLINDER BLOCK MAIN JOURNAL BORE DIAMETER SPECIFICATION

      Mark "0" 66.020-66.022 mm (2.59922-2.59929 in.)
      Mark "1" 66.022-66.024 mm (2.59929-2.59936 in.)
      Mark "2" 66.024-66.026 mm (2.59936-2.59944 in.)
      Mark "3" 66.026-66.028 mm (2.59944-2.59952 in.)
      Mark "4" 66.028-66.030 mm (2.59952-2.59960 in.)
      Mark "5" 66.030-66.032 mm (2.59960-2.59968 in.)
      Mark "6" 66.032-66.034 mm (2.59968-2.59976 in.)
      Mark "7" 66.034-66.036 mm (2.59976-2.59984 in.)

      Crankshaft main journal diameter (B): 

      CRANKSHAFT MAIN JOURNAL DIAMETER SPECIFICATION

      Mark "0" 61.998-62.000 mm (2.44086-2.44094 in.)
      Mark "1" 61.996-61.998 mm (2.44078-2.44086 in.)
      Mark "2" 61.994-61.996 mm (2.44070-2.44078 in.)
      Mark "3" 61.992-61.994 mm (2.44063-2.44070 in.)
      Mark "4" 61.990-61.992 mm (2.44055-2.44063 in.)
      Mark "5" 61.988-61.990 mm (2.44047-2.44055 in.)
      Mark "6" 61.986-61.988 mm (2.44039-2.44047 in.)
      Mark "7" 61.984-61.986 mm (2.44031-2.44039 in.)

      Standard bearing center wall thickness: 

      STANDARD BEARING CENTER WALL THICKNESS SPECIFICATION

      Mark "1" 1.994-1.997 mm (0.0785-0.0786 in.)
      Mark "2" 1.997-2.000 mm (0.0786-0.0787 in.)
      Mark "3" 2.000-2.003 mm (0.0787-0.0789 in.)
      Mark "4" 2.003-2.006 mm (0.0789-0.0790 in.)
      Mark "5" 2.006-2.009 mm (0.0790-0.0791 in.)
    11. Completely remove the Plastigage.
  20. REMOVE CRANKSHAFT 
    1. Lift out the crankshaft
    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.

      3. Fig 19: Removing Crankshaft
      G02948516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. 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 20: Checking Fit Between Piston And Piston Pin
    G02948517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE PISTON RINGS 
    1. Using a piston ring expander, remove the 2 compression rings.
      2. Fig 21: Using Piston Ring Expander To Remove Compression Rings
      G02948518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 side rails and oil ring expander by hand.

    HINT:

    Arrange the piston rings in correct order only.

  23. DISCONNECT CONNECTING ROD FROM PISTON 
    1. Using a small screwdriver, remove the 2 snap rings.
      2. Fig 22: Removing Snap Rings
      G02948519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

      HINT:

      • The piston and pin are a matched set.
      • Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
      Fig 23: Lightly Taping Out Piston Pin And Removing Connecting Rod
      G02948520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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