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Disassembly [10/2015 - ]: 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.
      GTY632922Courtesy 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.)

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

  2. INSPECT CONNECTING ROD OIL CLEARANCE 
    1. Place paint marks on the connecting rod and connecting rod cap so that they can be reinstalled to their original locations.
      GTY664272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
    2. Remove the 2 connecting rod bolts and connecting rod cap.
      GTY632887Courtesy 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.

      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.
      GTY628004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
    6. Install the connecting rod cap.

      See step  10

      NOTE:

      Do not turn the crankshaft.

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

      HINT: 

      Keep the connecting rod bearing and connecting rod cap together.

    8. Measure the Plastigage at its widest point.
      GTY634422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
      *b Number Mark

      Standard Oil Clearance

      0.035 to 0.068 mm (0.00138 to 0.00268 in.)

      Maximum Oil Clearance

      0.07 mm (0.00276 in.)

      NOTE:

      Remove the Plastigage completely after the measurement.

      If the oil clearance is more than the maximum, replace the connecting rod bearing. If necessary, grind or replace the crankshaft.

      HINT: 

      If replacing a connecting rod bearing, select a new one with the same number as that which is marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" or "3" accordingly.

      Standard Crank Pin Diameter

      51.492 to 51.500 mm (2.0272 to 2.0276 in.)

      Standard Connecting Rod Big End Inside Diameter

      Mark Specified Condition
      1 54.500 to 54.508 mm (2.1457 to 2.1460 in.)
      2 54.509 to 54.516 mm (2.1460 to 2.1463 in.)
      3 54.517 to 54.524 mm (2.1463 to 2.1466 in.)

      Standard Size Bearing Center Wall Thickness

      Mark Specified Condition
      1 1.486 to 1.490 mm (0.0585 to 0.0587 in.)
      2 1.491 to 1.494 mm (0.0587 to 0.0588 in.)
      3 1.495 to 1.498 mm (0.0589 to 0.0590 in.)
    9. Perform the inspection above for each cylinder.
  3. REMOVE PISTON WITH CONNECTING ROD 
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
      GTY632908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 connecting rod bolts, 4 connecting rod caps and 4 lower connecting rod bearings.
    3. Push the piston, connecting rod and connecting rod bearing out through the top of the cylinder block sub-assembly.

      HINT: 

      • Keep the connecting rod bearings, 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 rods and connecting rod caps.

      HINT: 

      Arrange the removed parts in the correct order.

  5. INSPECT CRANKSHAFT THRUST CLEARANCE 
    1. Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.
      GTY632912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Thrust Clearance

      0.04 to 0.24 mm (0.00157 to 0.00945 in.)

      Maximum Thrust Clearance

      0.30 mm (0.0118 in.)

      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

      1.93 to 1.98 mm (0.0760 to 0.0780 in.)

  6. REMOVE CRANKSHAFT 
    1. Uniformly loosen and remove the 10 crankshaft bearing cap bolts in several steps in the order shown in the illustration.
      Fig 1: Crankshaft Bearing Cap Bolts Loosening Sequence
      GTY658947Courtesy 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 crankshaft bearing caps in the correct order.
    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.

  7. REMOVE CRANKSHAFT THRUST WASHER 
    1. Remove the 2 crankshaft thrust washers from the cylinder block sub-assembly.
      GTY632903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE CRANKSHAFT BEARING 
    1. Remove the crankshaft bearings from the cylinder block sub-assembly and crankshaft bearing caps.

      HINT: 

      Arrange the crankshaft bearings in the correct order.

  9. REMOVE CRANKSHAFT PULLEY SET KEY 
    1. Using a screwdriver, remove the 2 crankshaft pulley set keys from the crankshaft.
  10. REMOVE PISTON RING SET 
    1. Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring.
      GTY500725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Piston Ring Expander
    2. Remove the oil ring expander and 2 oil ring side rails by hand.

      HINT: 

      Arrange the removed parts in the correct order.

  11. REMOVE PISTON PIN HOLE SNAP RING 
    1. Insert a small screwdriver into the cutout and pry out the piston pin hole snap ring (front side).
      GTY506095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

      Do not remove the snap ring (rear side) unless necessary.

      HINT: 

      Tape the screwdriver tip before use.

  12. REMOVE PISTON 
    1. Heat the piston to between 80 and 90°C (176 to 194°F).
    2. Using a plastic hammer and brass bar, lightly tap out the piston pin. Then remove the connecting rod.

      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.
  13. REMOVE OIL PIPE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon wrench, remove the 4 hexagon socket head cap bolts.
      GTY510964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Hexagon Socket Head Cap Bolt
      Bolt
    2. Remove the 3 bolts and oil pipe sub-assembly from the cylinder block sub-assembly.
    3. Remove the oil pipe gasket from the oil pipe sub-assembly.
  14. REMOVE STUD BOLT 
    NOTE:

    If a stud bolt is deformed or its threads are damaged, replace it.

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