Cylinder Block: Disassembly

WARNING: This page is about a different car, the 2004 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

Install Engine To Engine Stand For Disassembly
Remove Timing Chain (See REMOVAL ).
Remove Cylinder Head See REMOVAL .
Remove Knock Sensor See KNOCK SENSOR .
Remove Engine Wire Clamps
Remove Plug
Remove OCV Filter
Using a 12 mm hexagon wrench, remove the plug, gasket and OCV filter.

Fig 1: Removing Plug, Gasket & OCV Filter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove Water Pump See REMOVAL .
Remove Thermostat See REMOVAL .
Remove Engine Coolant Drain Union
Remove Oil Dipstick & Guide
1. Remove the bolt, oil dipstick and guide.
2. Remove the O-ring from the oil dipstick.
Fig 2: Removing Oil Dipstick & Guide
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove Water Bypass Pipe
Remove the 2 nuts, bolt, water bypass pipe and gasket.

Fig 3: Removing Water Bypass Pipe
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove Oil Pump See REMOVAL .
Remove Oil Filter See REPLACEMENT .
Remove Oil Filter Union
Using a 12 mm hexagon wrench, remove the oil filter union.

Fig 4: Removing Oil Filter Union
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check Balance Shaft Thrust Clearance
Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
- Standard Thrust Clearance: 0.050-0.090 mm (0.00197-0.00354 in.)
- Maximum Thrust Clearance: 0.090 mm (0.00354 in.)
If the thrust clearance is greater than maximum, replace the balance shaft housing and bearings. If necessary, replace the balance shaft.

Fig 5: Measuring Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove Balance Shaft Housing & Check Oil Clearance

Uniformly loosen and remove the 8 bolts in several passes, in the sequence shown in Fig 6.

Fig 6: Removing Balance Shaft Housing Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the balance shaft housing is difficult to lift up, pry between the balance shaft housing and crank case with a screwdriver.

NOTE: Be careful not to damage the contact surfaces of the balance shaft housing and crank case.

HINT: Keep the lower bearing and balance shaft housing together.
Lift out the No. 1 and No. 2 balance shafts.
HINT: Keep the upper bearing with the crank case.
Clean each bearing and journal.
Check each bearing and journal for pitting and scratches.
If the bearing or journal is damaged, replace the bearings. If necessary, replace the balance shaft.
Place the No. 1 and No. 2 balance shafts on the crank case.
Lay a strip of Plastigage across each journal.

Fig 7: Laying Strip Of Plastigage Across Each Journal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the balance shaft housing. See REASSEMBLY .
NOTE: Do not turn the balance shaft.
Remove the balance shaft housing. See step a above.
Measure the Plastigage at its widest point.
Standard Clearance: 0.004-0.049 mm (0.00016-0.00192 in.)

If the oil clearance is greater than standard, replace the bearings.

If necessary, replace the balance shaft.

Fig 8: Measuring Plastigage At Widest Point
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT: If using a standard bearing, replace it with one having the same number.

Balance Shaft Housing Journal Diameter

Mark 1	26.000-26.006 mm (1.02362-1.02386 in.)
Mark 2	26.007-26.012 mm (1.02390-1.02409 in.)
Mark 3	26.013-26.018 mm (1.02413-1.02433 in.)

Balance Shaft Journal Diameter: 22.985-23.000 mm (0.90492-0.90551 in.)

Standard Bearing Center Wall Thickness

Mark 1	1.486-1.489 mm (0.05850-0.05862 in.)
Mark 2	1.490-1.492 mm (0.05866 to 0.05874 in.)
Mark 3	1.493-1.495 mm (0.05877 to 0.05885 in.)

Fig 9: Replacing Balance Shaft

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove Balance Shaft
1. Lift out the balance shaft.
2. Remove the 4 upper bearings from the crank case.
  HINT: Arrange the bearings in the correct order.
Remove Crank Case
1. Uniformly loosen and remove the 11 bolts in several passes, in the sequence shown in Fig 10.
  
  Fig 10: Removing Crank Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, remove the crank case by prying the portions between the crank case and cylinder block.
  NOTE: Be careful not to damage the contact surfaces of the crank case and cylinder block.
  
  Fig 11: Removing Crank Case By Prying
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the O-ring.
Remove Crankshaft Rear Oil Seal
Check Connecting Rod Thrust Clearance
Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
- Standard Thrust Clearance: 0.160-0.362 mm (0.0063-0.0143 in.)
- Maximum Thrust Clearance: 0.362 mm (0.0143 in.)
Fig 12: Measuring Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Connecting Rod Thickness: 19.788-19.840 mm (0.7791-0.7811 in.)

Remove Connecting Rod Caps & Check Oil Clearance

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

Fig 13: Checking Matchmarks On Connecting Rod & Cap Are Aligned
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the 2 connecting rod cap bolts.
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.

Fig 14: Removing Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 on the crank pin.

Fig 15: Laying Strip Of Plastigage On Crank Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the connecting rod cap. See REASSEMBLY .

Fig 16: Installing Connecting Rod Cap Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Do not turn the crankshaft.
Remove the connecting rod cap. See steps b and c above.

Measure the Plastigage at its widest point.

Standard Oil Clearance: 0.024-0.048 mm (0.0009-0.0019 in.)
Maximum Oil Clearance: 0.08 mm (0.0031 in.)

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

Fig 17: Measuring Plastigage At Its Widest Point

HINT: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked 1, 2 and 3 accordingly.

Fig 18: Locating Mark On Bearing & Bearing Cap

Reference:

STANDARD BEARING CENTER WALL THICKNESS

Mark 1	1.485-1.488 mm (0.0585-0.0586 in.)
Mark 2	1.489-1.491 mm (0.0586-0.0587 in.)
Mark 3	1.492-1.494 mm (0.0586-0.0587 in.)

Completely remove the Plastigage.

Remove Piston & Connecting Rod Assemblies
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
  
  Fig 19: Removing Carbon From Top Of Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
- Arrange the piston and connecting rod assemblies in the correct order.
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: 0.040-0.240 mm (0.0016-0.0094 in.)
- Maximum Thrust Clearance: 0.30 mm (0.0118 in.)
Fig 20: Measuring Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Thrust Washer Thickness: 1.930-1.980 mm (0.0760-0.0780 in.)
Remove Main Bearing Caps & Check Oil Clearance
1. Uniformly loosen and remove the 10 main bearing cap bolts in several passes, in the sequence shown. See Fig 21.
  
  Fig 21: Removing Main Bearing Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using the 2 removed main bearing cap bolts, remove the 5 main bearing caps and 5 lower bearings.
  
  Fig 22: Removing Main Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the cylinder block.
  
  HINT:
  - Keep the lower bearing and main bearing cap together.
  - Arrange the main bearing caps in the correct order.
3. Lift out the crankshaft.
  HINT: Keep the main bearings and 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, replace the crankshaft.
6. Place the crankshaft on the cylinder block.
7. Lay a strip of Plastigage across each journal.
  
  Fig 23: Laying Strip Of Plastigage Across Each Journal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Install the main bearing caps. See REASSEMBLY .
  
  Fig 24: Installing Main Bearing Caps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not turn the crankshaft.
9. Remove the main bearing cap. See procedure a and b above.
10. Measure the Plastigage at its widest point.
  Standard Oil Clearance: 0.017-0.040 mm (0.0007-0.0016 in.)
  
  Maximum Oil Clearance: 0.050 mm (0.0020 in.)
  
  If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.
  
  Fig 25: Measuring Plastigage At Widest Point
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. If using a standard bearing, replace it 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 selecting the bearing with the same number as the total. There are 4 sizes of standard bearings, marked 1, 2, 3 and 4 accordingly.
  EXAMPLE: Cylinder Block "4" + Crankshaft "3" = Total Number 7 (Use Bearing "3")
  
  Fig 26: Bearing Number Reference Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 27: Locating Number Markings On Crankshaft, Bearing & Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 28: Main Bearing Reference Specifications Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Completely remove the Plastigage.
Remove Crankshaft
1. Lift out the crankshaft.
2. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block.
  HINT: Arrange the main bearings and thrust washers in the correct order.
Check Fit Between Piston & 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 29: Checking Fit Between Piston & Piston Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove Piston Rings
1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the 2 side rails and oil ring by hand.
  HINT: Arrange the piston rings in the correct order only.
  
  Fig 30: Removing Piston Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Disconnect Connecting Rod From Piston
1. Using a small screwdriver, pry out the 2 snap rings.
  
  Fig 31: Prying Out Snap Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Gradually heat the piston to 80-90°C (176-194°F).
  
  Fig 32: Heating Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic-faced hammer and a brass bar, lightly tap out the piston pin and remove the connecting rod.
  
  Fig 33: Tapping Out Piston Pin & Removing Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
HINT:
- The piston and pin are a matched set.
- Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.