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Disassembly [11/2017 - ]: 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 0.0157 in.)

      Maximum Thrust Clearance

      0.50 mm (0.0197 in.)

      HINT: 

      If the thrust clearance is more than the maximum, replace the connecting rod sub-assembly. 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 bolts, remove the connecting rod cap and lower connecting rod bearing by wiggling the connecting rod cap right and left.
      GTY552391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Keep the lower connecting rod bearing installed to the connecting rod cap.

    4. Clean the crank pin and connecting rod bearing.
    5. Check the crank pin and connecting rod bearing for pitting or scratches.
    6. Lay a strip of Plastigage on the crank pin.
      GTY822742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
    7. Ensure 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 with the 2 connecting rod bolts.

      See step  9

      NOTE:

      Do not turn the crankshaft.

    9. Remove the 2 connecting rod 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.)

      HINT: 

      • If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.
      • If replacing a connecting rod bearing, select a new one with the same number as marked on the connecting rod cap. There are 4 sizes of standard connecting rod bearings, marked "1", "2", "3" or "4" accordingly.
      GTY784142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Number Mark

      Standard Connecting Rod Diameter

      Mark Specified Condition
      1 56.000 to 56.006 mm (2.20472 to 2.20496 in.)
      2 56.007 to 56.012 mm (2.20500 to 2.20519 in.)
      3 56.013 to 56.018 mm (2.20523 to 2.20543 in.)
      4 56.019 to 56.024 mm (2.20547 to 2.20566 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 0.0587 in.)
      4 1.490 to 1.493 mm (0.0587 to 0.0588 in.)

      Standard Crankshaft Pin Diameter

      52.992 to 53.000 mm (2.08630 to 2.08661 in.)

      NOTE:

      Completely remove the Plastigage after the measurement.

  3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD 
    1. Using a ridge reamer, remove all of the carbon from the top of the cylinder.
      GTY822022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Ridge Reamer
    2. Push the piston, connecting rod sub-assembly and upper connecting rod bearing through the top of the cylinder block sub-assembly.

      HINT: 

      • Keep the connecting rod bearing, connecting rod sub-assembly and connecting rod cap together.
      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.
  4. REMOVE CONNECTING ROD BEARING 
    1. Remove the connecting rod bearings from the connecting rod and connecting rod cap.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  5. REMOVE CRANKSHAFT 
    1. Uniformly loosen and remove the 8 crankshaft bearing cap set bolts and 8 seal washers in several steps in the order shown in the illustration.
      Fig 1: Crankshaft Bearing Cap Set Bolts Loosening Sequence
      GTY803262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Uniformly loosen the 16 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.
      Fig 2: Crankshaft Bearing Cap Set Bolts Loosening Sequence
      GTY568423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver with its tip wrapped with protective tape, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and 4 lower crankshaft bearings as a set.
      GTY552401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Push up the crankshaft bearing cap slowly and evenly, alternating between the right and left side so that the crankshaft bearing cap can be removed.
      • Be careful not to damage the contact surfaces of the cylinder block sub-assembly and the crankshaft bearing cap.
    4. Remove the crankshaft.
  6. REMOVE CRANKSHAFT BEARING 
    1. Remove the 4 upper crankshaft bearings and 4 lower crankshaft bearings.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  7. REMOVE CRANKSHAFT THRUST WASHER SET 
    1. Remove the crankshaft thrust washer set 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 No. 1 compression ring and No. 2 compression ring.
      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 such a way that they can be reinstalled to their original locations.

  9. REMOVE PISTON SUB-ASSEMBLY WITH PIN 
    1. Remove the connecting rod from the piston.
      GTY552392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver, pry out the piston pin hole snap ring (front side).
        NOTE:
        • Do not remove the piston pin hole snap ring (rear side) unless it has to be replaced.
        • Be careful not to damage the piston when removing the piston pin hole snap ring (rear side).
      2. Gradually heat the piston to approximately 80°C (176°F).
        WARNING:

        Be sure to wear protective gloves.

      3. Using a brass bar and a hammer, lightly tap out the piston pin and remove the connecting rod.
        GTY162022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT: 

        • The piston and piston pin are a matched set.
        • Arrange the removed parts in such a way that they can be reinstalled to their original locations.
    2. Using a gasket scraper, remove any carbon from the piston top.
      NOTE:

      Be careful not to scratch the piston.

    3. Using a groove cleaning tool or a 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 socket wrench, remove the 3 bolts and 3 No. 1 oil nozzle sub-assemblies.
      GTY552400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the 3 No. 1 oil nozzle sub-assemblies for damage or clogging.

      HINT: 

      If there is damage or clogs, 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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