Engine Unit: Disassembly

WARNING: This page is about a different car, the 2007 Lexus SC 430. However, it is still accessible from the selected car via links, so may be relevant.

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 SPARK PLUG
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH (See REMOVAL )
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (See REMOVAL )
REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY (See REMOVAL )
REMOVE NO. 2 TIMING BELT COVER SUB-ASSEMBLY (See REMOVAL )
REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (See REMOVAL )
REMOVE IDLER PULLEY ASSEMBLY (See REMOVAL )
REMOVE CRANKSHAFT PULLEY (See REMOVAL )
REMOVE NO. 1 TIMING BELT COVER (See REMOVAL )
REMOVE CRANKSHAFT POSITION SENSOR PLATE (See REMOVAL )
REMOVE TIMING GEAR COVER SPACER (See REMOVAL )
REMOVE TIMING BELT (See REMOVAL )
REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
1. Using a 10 mm hexagon wrench, remove the bolt, idler and plate washer.
REMOVE NO. 2 TIMING BELT IDLER SUB-ASSEMBLY
1. Remove the bolt and idler.
REMOVE CRANKSHAFT TIMING PULLEY
1. Using SST, remove the timing pulley.
  
  Fig 1: Removing Timing Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010)
  
  NOTE: Do not turn the timing pulley.
REMOVE SEMICIRCULAR PLUG
REMOVE CAMSHAFT TIMING PULLEY SUB-ASSEMBLY RH (See REMOVAL )
REMOVE CAMSHAFT TIMING PULLEY SUB-ASSEMBLY LH (See REMOVAL )
REMOVE REAR NO. 2 TIMING BELT PLATE RH (See REMOVAL )
REMOVE REAR TIMING BELT PLATE RH (See REMOVAL )
REMOVE REAR NO. 2 TIMING BELT PLATE LH (See REMOVAL )
REMOVE REAR TIMING BELT PLATE LH (See REMOVAL )
REMOVE CAMSHAFT (See REMOVAL )
REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY (See REMOVAL )
REMOVE CYLINDER HEAD SUB-ASSEMBLY
1. Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes, in the sequence shown in the illustration.
  
  Fig 2: Identifying Loosening Sequence Of Cylinder Head Bolts (RH Bank)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Cylinder head warpage or cracking could result from removing bolts in the incorrect order.
  - Be careful not to drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
    
    Fig 3: Identifying Portion A (RH Bank)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.
  HINT:
  
  If the cylinder head cannot be removed, pry between the cylinder head and cylinder block with a screwdriver.
  
  NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
  
  Fig 4: Prying Between Cylinder Head And Cylinder Block With Screwdriver (RH Bank)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD GASKET
REMOVE CYLINDER HEAD LH
1. Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes, in the sequence shown in the illustration.
  
  Fig 5: Identifying Loosening Sequence Of Cylinder Head Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Cylinder head warpage or cracking could result from removing bolts in the incorrect order.
  - Be careful not to drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
    
    Fig 6: Identifying Portion A (LH Bank)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.
  HINT:
  
  If the cylinder head cannot be removed, pry between the cylinder head and cylinder block with a screwdriver.
  
  NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
  
  Fig 7: Prying Between Cylinder Head And Cylinder Block With Screwdriver (LH Bank)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CYLINDER HEAD GASKET
REMOVE WATER PUMP ASSEMBLY (See INSPECTION )
REMOVE NO. 2 OIL PAN SUB-ASSEMBLY (See REMOVAL )
REMOVE OIL PAN BAFFLE PLATE (See REMOVAL )
REMOVE OIL PAN SUB-ASSEMBLY (See REMOVAL )
REMOVE OIL STRAINER SUB-ASSEMBLY (See REMOVAL )
REMOVE OIL PUMP ASSEMBLY (See REMOVAL )
REMOVE ENGINE 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.
  
  Fig 8: Locating Engine Rear Oil Seal Retainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the O-ring.
REMOVE VALVE LIFTER (See REMOVAL )
REMOVE INTAKE VALVE (See DISASSEMBLY )
REMOVE EXHAUST VALVE (See DISASSEMBLY )
REMOVE VALVE STEM OIL SEAL (See DISASSEMBLY )
REMOVE CAMSHAFT TIMING TUBE ASSEMBLY (See DISASSEMBLY )
REMOVE CAMSHAFT SUB GEAR (See DISASSEMBLY )
REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
1. Remove the RH and LH drain cocks.
2. Remove the 2 nuts.
3. Pry out the seal plate.
  
  Fig 9: Locating Cylinder Block Drain Cock And Water Seal Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CONNECTING ROD THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
  Standard thrust clearance: 0.160 to 0.290 mm (0.0063 to 0.0138 in.)
  
  Maximum thrust clearance: 0.35 mm (0.0138 in.)
  
  If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
  
  Connecting rod thickness: 22.880 to 22.920 mm (0.9008 to 0.9024 in.)
  
  Fig 10: Inspecting Connecting Rod Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CONNECTING ROD OIL CLEARANCE

Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
Remove the 2 connecting rod cap bolts.

Fig 11: Locating Connecting Rod Cap Bolts
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.

Fig 12: Removing Connecting Rod Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Lay a strip of Plastigage across the crank pin.

Fig 13: Laying Strip Of Plastigage Across Crank Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the connecting rod cap with the 2 bolts.
Remove the 2 bolts, connecting rod cap and lower bearing.

Fig 14: Locating Connecting Rod Cap With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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: 0.065 mm (0.0026 in.)

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

Fig 15: 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.

Standard Bearings

BEARINGS SPECIFICATION

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 SPECIFICATION

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

Fig 16: Identifying Number Marks

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

EXAMPLE:

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

Connecting rod big end inside diameter

CONNECTING ROD BIG END INSIDE DIAMETER REFERENCE

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.)

Crankshaft crank pin diameter

CRANKSHAFT CRANK PIN DIAMETER REFERENCE

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

THICKNESS CHART

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.

INSPECT CRANKSHAFT THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
  Standard thrust clearance: 0.020 to 0.220 mm (0.0008 to 0.0087 in.)
  
  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.
  
  Thrust washer thickness: 2.440 to 2.490 mm (0.0961 to 0.0980 in.)
  
  Fig 17: Inspecting Crankshaft Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CRANKSHAFT OIL CLEARANCE

Remove the 10 crankshaft bearing cap bolts.

Fig 18: Locating Crankshaft Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Uniformly loosen and remove the 20 crankshaft bearing cap bolts in the sequence shown in the illustration.

Fig 19: Identifying Loosening Sequence Of Crankshaft Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using 2 screwdrivers, pry out the crankshaft bearing caps, 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 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 20: Removing Crankshaft Bearing Caps
  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.
Install the 10 crankshaft bearings and 5 crankshaft bearing caps with the 30 bolts. Do not install the crankshaft.

Fig 21: Installing Crankshaft Bearings And Crankshaft Bearing Caps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a cylinder gauge, measure the inside diameter of the crankshaft bearing.
Bearing inside diameter: 66.986 to 67.000 mm (2.6372 to 2.6378 in.)
Measure the diameter of the crankshaft journal.

Fig 22: Measuring Inside Diameter Of Crankshaft Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Subtract the crankshaft journal diameter measurement from the crankshaft bearing inside diameter measurement.

Standard clearance

CLEARANCE SPECIFICATION

Number Mark	Specified Condition
No. 1 and No. 5	0.017 to 0.033 mm (0.0007 to 0.0013 in.)
Other	0.029 to 0.045 mm (0.0011 to 0.0018 in.)

Maximum clearance

CLEARANCE SPECIFICATION

Number Mark	Specified Condition
No. 1 and No. 5	0.043 mm (0.0017 in.)
Other	0.055 mm (0.0022 in.)

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

Fig 23: Identifying Crankshaft Bearing Number Marks

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 cylinder block and crankshaft, and then refer to the table 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, No. 5

CYLINDER BLOCK AND CRANKSHAFT SPECIFICATION

(A) + (B)	Upper	Lower
0 to 5	3	3
6 to 8	3	4
9 to 11	4	4
12 to 14	4	5
15 to 17	5	5
18 to 20	5	6
21 to 23	6	6
24 to 26	6	7
27 to 28	7	7

EXAMPLE:

Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "4" (Upper), "5" (Lower))

Other

CYLINDER BLOCK AND CRANKSHAFT SPECIFICATION

(A) + (B)	Upper	Lower
0 to 5	1	1
6 to 8	1	2
9 to 11	2	2
12 to 14	2	3
15 to 17	3	3
18 to 20	3	4
21 to 23	4	4
24 to 26	4	5
27 to 28	5	5

EXAMPLE:

Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "2" (Upper), "3" (Lower))

Cylinder block crankshaft journal bore diameter (A)

CYLINDER BLOCK CRANKSHAFT JOURNAL BORE DIAMETER SPECIFICATION

Number Mark	Specified Condition
Mark 00	72.000 mm (2.8346 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.)

Crankshaft journal diameter (B)

CRANKSHAFT JOURNAL DIAMETER REFERENCE

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

THICKNESS CHART

Number Mark	Specified Condition
Mark 3	2.492 to less than 2.495 mm (0.0981 to less than 0.0982 in.)
Mark 4	2.495 to less than 2.498 mm (0.0982 to less than 0.0983 in.)
Mark 5	2.498 to less than 2.501 mm (0.0983 to less than 0.0985 in.)
Mark 6	2.501 to less than 2.504 mm (0.0985 to less than 0.0986 in.)
Mark 7	2.504 to less than 2.507 mm (0.0986 to less than 0.0987 in.)

Other

THICKNESS CHART

Number Mark	Specified Condition
Mark 1	2.486 to less than 2.489 mm (0.0979 to less than 0.0980 in.)
Mark 2	2.489 to less than 2.492 mm (0.0980 to less than 0.0981 in.)
Mark 3	2.492 to less than 2.495 mm (0.0981 to less than 0.0982 in.)
Mark 4	2.495 to less than 2.498 mm (0.0982 to less than 0.0983 in.)
Mark 5	2.498 to less than 2.501 mm (0.0983 to less than 0.0985 in.)

Remove the 30 bolts, 5 crankshaft bearing caps and 5 lower crankshaft bearings.
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.

Fig 24: Removing Crankshaft Bearing Caps And Lower Crankshaft Bearings And Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 25: Grinding Top Of Cylinder
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 26: Checking Piston And 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.
3. Remove the 2 side rails and expander by hand.
  
  Fig 27: Removing No. 1 And No. 2 Piston Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a small screwdriver, pry out the 2 snap rings.
  
  Fig 28: Installing Snap Ring On Other Side Of Piston Pin Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Gradually heat the piston to approximately 60°C (140°F).
  
  Fig 29: 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 30: Removing Connecting Rod
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002