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Disassembly [10/2018 - ]: Procedure

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  1. REMOVE NO. 1 VENTILATION CASE 
    WARNING:

    Do not diassembly except if the No. 1 ventilaion case to be damaged.

    1. Remove the 4 bolts and No. 1 ventilation case from the cylinder block sub-assembly.
      GTY837282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 oil separator gaskets from the No. 1 ventilation case.
      GTY809933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE CYLINDER BLOCK WITH HEAD STRAIGHT SCREW PLUG 
    1. Using a 10 mm hexagon socket wrench, remove the cylinder block with head straight screw plug and gasket from the cylinder.
      GTY820720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT CONNECTING ROD THRUST CLEARANCE 
    1. Using a dial indicator, measure the thrust clearance while moving the connecting rod sub-assembly back and forth.
      GTY837134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Thrust Clearance

      0.160 to 0.512 mm (0.00630 to 0.0202 in.)

      Maximum Thrust Clearance

      0.512 mm (0.0202 in.)

      HINT: 

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

  4. INSPECT CONNECTING ROD OIL CLEARANCE 
    1. Note the alignment marks on the connecting rod and connecting rod cap so that they can be reinstalled to their original locations.
      GTY819612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark
    2. Using an E12 "TORX" socket wrench, remove the 2 connecting rod bolts and connecting rod cap.
      GTY837133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Keep the connecting rod bearing and connecting rod cap together.

    3. Clean the crank pin and connecting rod bearing.
    4. Check the crank pin and connecting rod bearing for pitting and scratches.

      HINT: 

      If the crank pin or connecting rod bearing is damaged, replace the connecting rod bearings. If necessary, replace the crankshaft.

    5. Lay a strip of Plastigage on the crank pin.
      GTY781082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
    6. Check that the front mark of the connecting rod cap is facing the correct direction, and install the connecting rod cap to the connecting rod.
      GTY794169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark
    7. Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.
      GTY837133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using an E12 "TORX" socket wrench, install and alternately tighten the 2 connecting rod bolts in several steps.

      Torque: 38 N.m (387 kgf/cm, 28 ft.lbf) 

    9. Mark the front of each connecting rod bolt with paint.
      Fig 1: Tighten Connecting Rod Cap Bolts Alternately Using Paint Marks And Degrees (Step Two)
      GTY757623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b 90°
      Front of Engine
    10. Tighten the connecting rod bolts 90° as shown in the illustration.
      NOTE:

      Do not turn the crankshaft during the measurement.

    11. Remove the 2 connecting rod bolts and connecting rod cap.

      HINT: 

      Keep the connecting rod bearing and connecting rod cap together.

    12. Measure the Plastigage at its widest point.
      GTY788701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
      *b 1, 2 or 3 Mark

      Standard Oil Clearance

      0.032 to 0.065 mm (0.00126 to 0.00256 in.)

      Maximum Oil Clearance

      0.065 mm (0.00256 in.)

      HINT: 

      • If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, replace 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 3 sizes of standard connecting rod bearings, marked "1", "2" or "3" accordingly.

      Standard Connecting Rod Big End Inside Diameter

      Mark Specified Condition
      1 51.000 to 51.008 mm (2.00787 to 2.00818 in.)
      2 51.008 to 51.016 mm (2.00818 to 2.00850 in.)
      3 51.016 to 51.024 mm (2.00850 to 2.00881 in.)

      Standard Connecting Rod Bearing Center Wall Thickness

      Mark Specified Condition
      1 1.483 to 1.487 mm (0.058386 to 0.058543 in.)
      2 1.487 to 1.491 mm (0.058543 to 0.058701 in.)
      3 1.491 to 1.495 mm (0.058701 to 0.058858 in.)

      Standard Crank Pin Diameter

      47.992 to 48.000 mm (1.88945 to 1.88976 in.)

      NOTE:

      Remove the Plastigage completely after the measurement.

    13. Perform the inspection above for each cylinder.
  5. REMOVE PISTON WITH CONNECTING ROD 
    1. Using a ridge reamer, remove all the carbon from the top of each cylinder.
      GTY783278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Ridge Reamer
    2. Remove the 8 connecting rod bolts, 4 connecting rod caps and 4 connecting rod bearings.
    3. Push the 4 pistons, 4 connecting rods and 4 connecting rod bearings out through the top of the cylinder block sub-assembly.

      HINT: 

      • Keep the connecting rod bearings, connecting rods and connecting rod caps together.
      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.
  6. REMOVE CONNECTING ROD BEARING 
    1. Remove the 8 connecting rod bearings from the 4 connecting rods and 4 connecting rod caps.

      HINT: 

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

  7. INSPECT CRANKSHAFT THRUST CLEARANCE 
    1. Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.
      GTY820048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Thrust Clearance

      0.02 to 0.22 mm (0.000787 to 0.00866 in.)

      Maximum Thrust Clearance

      0.22 mm (0.00866 in.)

      HINT: 

      If the thrust clearance is more than the maximum, replace the crankshaft thrust washers as a set. If necessary, replace the crankshaft.

      Standard Thrust Washer Thickness

      2.415 to 2.470 mm (0.0951 to 0.0972 in.)

  8. REMOVE CRANKSHAFT 
    1. Uniformly loosen and remove the 10 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.
      Fig 2: Crankshaft Bearing Cap Set Bolt Loosening Sequence
      GTY799877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 crankshaft bearing caps from the cylinder block sub-assembly.

      HINT: 

      • Keep the No. 2 crankshaft bearings and crankshaft bearing caps together.
      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.
    3. Remove the crankshaft from the cylinder block sub-assembly.

      HINT: 

      Keep the crankshaft bearings and crankshaft thrust washers together with the cylinder block sub-assembly.

    4. Check each crankshaft journal and crankshaft bearing for pitting and scratches.

      If the journal or crankshaft bearing is damaged, replace the crankshaft bearings. If necessary, replace the crankshaft.

  9. REMOVE CRANKSHAFT THRUST WASHER 
    1. Remove the 2 crankshaft thrust washers from the No. 3 journal position of the cylinder block sub-assembly.
      GTY772181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE CRANKSHAFT BEARING 
    1. Remove the 5 No. 1 crankshaft bearings and 5 No. 2 crankshaft bearings from the cylinder block sub-assembly and 5 crankshaft bearing caps.

      HINT: 

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

  11. REMOVE PISTON RING SET 
    1. Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring from the piston.
      GTY768197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Piston Ring Expander
    2. Remove the oil ring expander, upper side rail and lower side rail from the piston by hand.

      HINT: 

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

  12. REMOVE PISTON PIN HOLE SNAP RING 
    1. Using a screwdriver, pry out the 2 piston pin hole snap rings from the piston.
      GTY791236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark Cutout Portion
      *b Protective Tape

      HINT: 

      Tape the screwdriver tip before use.

  13. REMOVE PISTON 
    1. Gradually heat each piston to between 80 and 90°C (176 to 194°F).
      GTY757106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      WARNING:

      Be sure to wear protective gloves.

    2. Using a brass bar and a hammer, lightly tap out the piston pin and remove the connecting rod.
      GTY757100Courtesy 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.
  14. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies from the cylinder block sub-assembly.
      GTY825010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 2 oil nozzle sub-assemblies from the cylinder block sub-assembly.
      GTY825009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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