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Disassembly [09/2014 - 11/2017]: Procedure

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  1. INSPECT CONNECTING ROD THRUST CLEARANCE 
    1. Using a dial indicator, measure the connecting rod thrust clearance while moving the connecting rod sub-assembly back and forth.
      GTY102441Courtesy 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 connecting rod 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 bolts.
      GTY464505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Engine Front
    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.
      GTY141730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Keep the lower connecting rod bearing inserted 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 and scratches.
    6. Lay a strip of Plastigage on the crank pin.
      GTY506967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
    7. Check that the front mark of the connecting rod cap is facing forward.
      GTY501286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark
      Engine Front
    8. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
    9. Install the connecting rod bolts.
      NOTE:

      Do not turn the crankshaft during the procedure.

      HINT: 

      The connecting rod bolts are tightened in 2 progressive steps.

    10. Step 1:
      1. Install and alternately tighten the connecting rod bolts of each connecting rod cap in several steps.

        Torque: 40 N.m (408 kgf/cm, 30 ft.lbf) 

        GTY125277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Step 2:
      1. Mark the front side of each connecting rod bolt with paint.
        GTY512836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Paint Mark
        *b 90°
        Engine Front
      2. Tighten the connecting rod bolts 90°.
    12. Check that the paint marks are now at a 90° angle to the front.
    13. Remove the 2 connecting rod bolts and connecting rod cap.
    14. Measure the Plastigage at its widest point.

      Standard Oil Clearance

      0.032 to 0.052 mm (0.00126 to 0.00205 in.)

      Maximum Oil Clearance

      0.070 mm (0.00276 in.)

      GTY501574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
      *b 1, 2, 3 or 4 Mark

      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, 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.

      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 (0.05831 to 0.05843 in.)
      2 1.484 to 1.487 mm (0.05843 to 0.05854 in.)
      3 1.487 to 1.490 mm (0.05854 to 0.05866 in.)
      4 1.490 to 1.493 mm (0.05866 to 0.05878 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.
      GTY437402Courtesy 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 sub-assemblies and connecting rod caps.

      HINT: 

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

  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.

      Standard Thrust Clearance

      0.04 to 0.24 mm (0.00157 to 0.00945 in.)

      Maximum Thrust Clearance

      0.30 mm (0.0118 in.)

      HINT: 

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

      Thrust Washer Thickness

      2.43 to 2.48 mm (0.0957 to 0.0976 in.)

      GTY104851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE CRANKSHAFT 
    1. Uniformly loosen and remove the 8 bolts and 8 seal washers in several steps in the order shown in the illustration.
      Fig 1: Crankshaft Bolts Loosening Sequence
      GTY461388Courtesy 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
      GTY470045Courtesy 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.
      GTY517082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cylinder Brock Sub-assembly
      *2 Crankshaft Bearing Cap
      *a Protective Tape
      *b Joint Surface
      NOTE:
      • Push up on the crankshaft bearing cap slowly and evenly, alternating from the right and left side so that the crankshaft bearing cap can be removed.
      • Be careful not to damage the joint surfaces of the cylinder block sub-assembly and the crankshaft bearing cap.

      HINT: 

      • Tape the screwdriver tip before use.
      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.
    4. Remove the crankshaft.
  7. REMOVE CRANKSHAFT BEARING 
    1. Remove the upper crankshaft bearings and lower crankshaft bearings.

      HINT: 

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

  8. REMOVE CRANKSHAFT THRUST WASHER SET 
    1. Remove the crankshaft thrust washer set from the cylinder block sub-assembly.
      GTY145649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE PISTON RING SET 
    1. Using a piston ring expander, remove the No. 1 compression ring, No. 2 compression ring and oil ring.
      GTY508669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Piston Ring Expander
    2. Remove the oil ring expander by hand.

      HINT: 

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

  10. REMOVE PISTON SUB-ASSEMBLY WITH PIN 
    1. Disconnect the connecting rod sub-assembly from the piston.
      GTY125270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver, pry out the piston pin hole snap rings from the piston.
      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 plastic hammer, lightly tap out the piston pin and remove the connecting rod sub-assembly.

        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.
        GTY162022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a gasket scraper, remove any 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.

  11. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon wrench, remove the 3 bolts and 3 No. 1 oil nozzle sub-assemblies.
      GTY462486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check each oil nozzle sub-assembly for damage or clogging.

      HINT: 

      If there is damage or clogs, replace the No. 1 oil nozzle sub-assembly.

  12. REMOVE CONNECTING ROD SMALL END BUSH 
    1. Using SST and a press, remove the connecting rod small end bush.
      GTY458971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09222-30010 
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