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Disassembly [11/2021 - ]: Procedure

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  1. REMOVE NO. 1 VENTILATION CASE 
    1. WARNING:
      • When the No. 1 ventilation case is fastened using only bolt A:

        Perform this procedure only when replacement of the No. 1 ventilation case is necessary.

      • When the No. 1 ventilation case is fastened using bolt B:

        Do not remove and install the No. 1 ventilation case.
      GTY1090642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt A *b Bolt B
      GTY997355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT CONNECTING ROD THRUST CLEARANCE 
    1. GTY1074935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a dial indicator, measure the thrust clearance while moving the connecting rod sub-assembly back and forth.

        Standard Thrust Clearance

        0.16 to 0.51 mm (0.00630 to 0.0201 in.)

        Maximum Thrust Clearance

        0.512 mm (0.0202 in.)

      2. If the thrust clearance is more than the maximum, replace the connecting rod. If necessary, replace the crankshaft.
  3. INSPECT CONNECTING ROD OIL CLEARANCE 

    HINT: 

    There are two types of connecting rod sub-assemblies; cracking connecting rods and other than cracking connecting rods.

    GTY1104336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *A except Cracking Connecting Rod *B Cracking Connecting Rod
    *a w/ Pin *b w/o Pin
    1. except Cracking Connecting Rod:
      GTY1205573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark *b Plastigage
      *c Front Mark *d 90°
      *e Front of Engine f Paint Mark
      1. Note the alignment marks on the connecting rod and connecting rod cap so that they can be reinstalled to their original locations.
      2. Using an E12 "TORX" socket wrench, remove the 2 connecting rod bolts and connecting rod cap.

        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.
      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.
      7. Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.
      8. Using an E12 "TORX" socket wrench, install and uniformly tighten the 2 connecting rod bolts.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      9. Using an E12 "TORX" socket wrench, alternately tighten the 2 connecting rod bolts.

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

      10. Mark the front of each connecting rod bolt with paint.
      11. Tighten the connecting rod bolts 90° as shown in the illustration.
        NOTE:

        Do not turn the crankshaft during the measurement.

      12. Check that the paint marks are now at a 90° angle to the front.
    2. Cracking Connecting Rod:
      GTY1205574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark *b Plastigage
      *c Front Mark *d 90°
      *e Front of Engine *f Paint Mark
      1. Note the alignment marks on the connecting rod and connecting rod cap so that they can be reinstalled to their original locations.
      2. Using an E12 "TORX" socket wrench, remove the 2 connecting rod bolts and connecting rod cap.

        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.
      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.
      7. Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.
      8. Using an E12 "TORX" socket wrench, install and uniformly tighten the 2 connecting rod bolts.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

        NOTE:

        Do not use electric or air powered tools.

      9. Using an E12 "TORX" socket wrench, alternately tighten the 2 connecting rod bolts.

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

      10. Mark the front of each connecting rod bolt with paint.
      11. Tighten the connecting rod bolts 90° as shown in the illustration.
        NOTE:

        Do not turn the crankshaft during the measurement.

      12. Check that the paint marks are now at a 90° angle to the front.
    3. GTY1075826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage *b 1, 2 or 3 Mark
      1. Using an E12 "TORX" socket wrench, remove the 2 connecting rod bolts and connecting rod bearing cap.
      2. Measure the Plastigage at its widest point.

        Standard Oil Clearance

        0.027 to 0.059 mm (0.00106 to 0.00232 in.)

        Maximum Oil Clearance

        0.059 mm (0.00232 in.)

        HINT: 

        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 51.009 to 51.016 mm (2.00822 to 2.00850 in.)
        3 51.017 to 51.024 mm (2.00854 to 2.00881 in.)

        Standard Connecting Rod Bearing Center Wall Thickness

        Mark Specified Condition
        1 1.487 to 1.491 mm (0.0585 to 0.0587 in.)
        2 1.492 to 1.495 mm (0.0587 to 0.0589 in.)
        3 1.496 to 1.499 mm (0.0589 to 0.0590 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.

      3. If the oil clearance is more than the maximum, replace the connecting rod bearings.
      4. Perform the inspection above for each cylinder.
  4. REMOVE PISTON WITH CONNECTING ROD 
    1. GTY1074747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Ridge Reamer - -
      1. Using a ridge reamer, remove all the carbon from the top of each cylinder.
    2. GTY1066491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE CONNECTING ROD BEARING 
    1. GTY997364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSPECT CRANKSHAFT THRUST CLEARANCE 
    1. GTY1075668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.

        Standard Thrust Clearance

        0.09 to 0.19 mm (0.00354 to 0.00748 in.)

        Maximum Thrust Clearance

        0.25 mm (0.00984 in.)

        Standard Thrust Washer Thickness

        2.43 to 2.48 mm (0.0957 to 0.0976 in.)

      2. If the thrust clearance is more than the maximum, replace the crankshaft thrust washers as a set. If necessary, replace the crankshaft.
  7. REMOVE CRANKSHAFT BEARING CAP 
    1. Fig 1: Crankshaft Bearing Cap Bolts Loosening Sequence
      GTY1074986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Uniformly loosen and remove the 10 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.
      2. While moving the crankshaft bearing cap back and forth using 2 crankshaft bearing cap set bolts, remove the crankshaft bearing cap together with the crankshaft bearing.
  8. REMOVE CRANKSHAFT 
    1. GTY997367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE CRANKSHAFT THRUST WASHER 
    1. GTY997360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE CRANKSHAFT BEARING 
    1. GTY997285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE PISTON RING SET 
    1. GTY1075924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Piston Ring Expander - -
      1. Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring from the piston.
      2. Remove the oil ring expander, upper side rail and lower side rail from the piston by hand.
  12. REMOVE PISTON PIN 
    1. GTY1075244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark Cutout Portion - -
      1. Using a screwdriver with its tip wrapped with protective tape, pry out the piston pin hole snap ring (front side) from the piston.
        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 each piston to between 80 and 90°C (176 and 194°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.
  13. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. GTY1075067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 5 mm hexagon socket wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies from the cylinder block sub-assembly.
  14. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY 
    1. GTY1075553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 5 mm hexagon socket wrench, remove the 4 bolts and 4 No. 2 oil nozzle sub-assemblies from the cylinder block sub-assembly.
  15. REMOVE RING PIN 
    NOTE:

    It is not necessary to remove the ring pins unless they are being replaced.
    1. GTY997290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE STRAIGHT PIN 
    NOTE:

    It is not necessary to remove the straight pins unless they are being replaced.
    1. GTY997300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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