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Disassembly [10/2017 - ]: Procedure

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  1. INSPECT CONNECTING ROD THRUST CLEARANCE 
    1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
      GTY552390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard thrust clearance

      0.15 to 0.40 mm (0.00591 to 0.01575 in.)

      Maximum thrust clearance

      0.50 mm (0.0197 in.)

      If the thrust clearance is more than the maximum, replace the connecting rod assemblies as necessary. If necessary, replace the crankshaft.

  2. INSPECT CONNECTING ROD OIL CLEARANCE 
    1. Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned.

      HINT: 

      The matchmarks on the connecting rod sub-assembly and connecting rod cap are guides for correct reassembly.

    2. Remove the 2 connecting rod cap bolts.
      GTY552389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      GTY552391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Keep the lower bearing inserted to the connecting rod cap.

    4. Clean the crank pin and bearing.
    5. Check the crank pin and bearing for pitting and scratches.
    6. Lay a strip of Plastigage on the crank pin.
      GTY822742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
    7. Check that the front mark of the connecting rod cap is facing forward.
      GTY780176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
      Engine Front
    8. Install the connecting rod cap (See step  9).
      NOTE:

      Do not turn the crankshaft.

    9. Remove the 2 connecting rod cap bolts and connecting rod cap.
    10. Measure the Plastigage at its widest point.
      GTY776974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage

      Standard oil clearance

      0.032 to 0.052 mm (0.00126 to 0.00205 in.)

      Maximum oil clearance

      0.070 mm (0.00276 in.)

      If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.

      HINT: 

      If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing standard thickness is indicated by a number (1, 2, 3 or 4) marked on its surface.

      GTY784142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Number Mark

      Standard Connecting Rod Diameter

      Mark Specified Condition
      1 56.000 to 56.006 mm (2.2047 to 2.2049 in.)
      2 56.006 to 56.012 mm (2.2049 to 2.2051 in.)
      3 56.012 to 56.018 mm (2.2051 to 2.2054 in.)
      4 56.018 to 56.024 mm (2.2054 to 2.2056 in.)

      Standard Connecting Rod Bearing Center Wall Thickness

      Mark Specified Condition
      1 1.481 to 1.484 mm (0.0583 to 0.0584 in.)
      2 1.484 to 1.487 mm (0.0584 to 0.0585 in.)
      3 1.487 to 1.490 mm (0.0585 to 0.0586 in.)
      4 1.490 to 1.493 mm (0.0586 to 0.0587 in.)

      Standard crankshaft pin diameter

      52.992 to 53.000 mm (2.0863 to 2.0866 in.)

      NOTE:

      Completely remove the Plastigage after the measurement.

  3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD 
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
      GTY822022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Ridge Reamer
    2. 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.
  4. REMOVE CONNECTING ROD BEARING 
    1. Remove the connecting rod bearings from the connecting rod sub-assemblies and connecting rod caps.

      HINT: 

      Arrange the removed parts in the correct order.

  5. REMOVE CRANKSHAFT 
    1. Uniformly loosen and remove the 8 crankshaft bearing cap bolts and 8 seal washers in several steps and in the sequence shown in the illustration.
      Fig 1: Crankshaft Bearing Cap Bolts Loosening Sequence (1 Of 2)
      GTY803262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Uniformly loosen the 16 crankshaft bearing cap bolts in several steps and in the sequence shown in the illustration.
      Fig 2: Crankshaft Bearing Cap Bolts Loosening Sequence (2 Of 2)
      GTY568423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and lower crankshaft bearings.
      GTY552401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Push up on the cap slowly and evenly, alternating from the right and left side so that the bearing cap can be removed.
      • Be careful not to damage the joint surfaces of the cylinder block and the crankshaft bearing cap.
    4. Remove the crankshaft.
  6. REMOVE CRANKSHAFT BEARING 
    1. Remove the upper crankshaft bearings and lower crankshaft bearings.

      HINT: 

      Arrange the removed parts in the correct order.

  7. REMOVE CRANKSHAFT THRUST WASHER SET 
    1. Remove the crankshaft thrust washers from the cylinder block sub-assembly.
      GTY145649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE PISTON RING SET 
    1. Using a piston ring expander, remove the 2 compression rings.
      GTY821586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Piston Ring Expander
    2. Remove the oil ring expander and 2 side rails by hand.

      HINT: 

      Arrange the removed parts in the correct order.

  9. REMOVE PISTON WITH PIN SUB-ASSEMBLY 
    1. Disconnect the connecting rod from the piston.
      GTY552392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver, pry off the piston pin hole snap rings from the piston.
      2. Gradually heat the piston to approximately 80°C (176°F).
      3. Using a brass bar and a plastic-faced hammer, lightly tap out the piston pin and remove the connecting rod sub-assembly.
        GTY162022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT: 

        • The piston and piston pin are a matched set.
        • Arrange the pistons, piston pins, connecting rods and connecting rod bearings in the correct order.
    2. Using a gasket scraper, remove the carbon from the piston top.
    3. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
    4. Using solvent and a brush, thoroughly clean the piston.
      NOTE:

      Do not use a wire brush.

  10. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon wrench, remove the 3 bolts and No. 1 oil nozzle sub-assemblies.
      GTY552400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the 3 No. 1 oil nozzles for damage or clogging.

      If necessary, replace the No. 1 oil nozzle sub-assembly.

  11. REMOVE CONNECTING ROD SMALL END BUSH 
    1. Using SST and a press, press out the connecting rod small end bush.
      GTY795562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09222-30010 
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