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Disassembly [12/2023 - ]: Procedure

WARNING: This page is about a different car, the 2024 Lexus TX 550h+. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSPECT CONNECTING ROD THRUST CLEARANCE 
    1. GTY1228901Courtesy 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

        0.15 to 0.40 mm (0.00591 to 0.0157 in.)

        Maximum Thrust Clearance

        0.50 mm (0.0197 in.)

      2. 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. GTY1241402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Plastigage
      *c Front Mark - -
      1. Check that the paint marks on the connecting rod and connecting rod bearing cap are aligned.

        HINT: 

        The paint marks on the connecting rod and connecting rod bearing cap are guides for correct reassembly.

      2. Remove the 2 connecting rod bolts.
      3. Using the 2 removed connecting rod bolts, remove the connecting rod bearing cap and lower connecting rod bearing by wiggling the connecting rod bearing cap right and left.

        HINT: 

        Keep the lower connecting rod bearing installed to the connecting rod bearing 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.
      7. Ensure that the front mark of the connecting rod bearing cap is facing forward.
      8. Install the connecting rod bearing cap with the 2 connecting rod bolts.

        See step  11

        NOTE:

        Do not turn the crankshaft.

      9. Remove the 2 connecting rod bolts and connecting rod bearing cap.

        See step  3

    2. GTY1236263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage *b Mark 1, 2, 3, or 4
      1. Measure the Plastigage at its widest point.

        Standard Oil Clearance

        0.045 to 0.067 mm (0.00177 to 0.00264 in.)

        Maximum Oil Clearance

        0.070 mm (0.00276 in.)

        HINT: 

        If replacing a connecting rod bearing, select a new one with the same number as marked on the connecting rod bearing cap. There are 4 sizes of standard connecting rod bearings, marked "1", "2", "3" or "4" accordingly.

        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 1.482 to 1.485 mm (0.05835 to 0.05846 in.)
        2 1.486 to 1.488 mm (0.05850 to 0.05858 in.)
        3 1.489 to 1.491 mm (0.05862 to 0.05870 in.)
        4 1.492 to 1.494 mm (0.05874 to 0.05882 in.)

        Standard Crankshaft Pin Diameter

        52.992 to 53.000 mm (2.08630 to 2.08661 in.)

        NOTE:

        Remove the Plastigage completely after the measurement.

      2. If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.
  3. REMOVE PISTON WITH CONNECTING ROD 
    1. GTY1239856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE CONNECTING ROD BEARING 
    HINT: 
    Arrange the removed parts in such a way that they can be reinstalled to their original locations.
    1. GTY1231540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE CRANKSHAFT BEARING CAP 
    1. Fig 1: Crankshaft Bearing Cap Loosening Sequence
      GTY1229508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cylinder Block Sub-assembly *2 Crankshaft Bearing Cap
      *a Contact Surface - -
      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.
      2. Uniformly loosen and remove the 16 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.
      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.
        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.
  6. REMOVE CRANKSHAFT 
    1. GTY1231573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE CRANKSHAFT BEARING 
    HINT: 
    Arrange the removed parts in such a way that they can be reinstalled to their original locations.
    1. GTY1231561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE CRANKSHAFT THRUST WASHER SET 
    1. GTY1239861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE PISTON RING SET 
    HINT: 
    Arrange the removed parts in such a way that they can be reinstalled to their original locations.
    1. GTY1232118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring.
      2. Remove the oil ring expander, upper side rail and lower side rail by hand.
  10. REMOVE PISTON PIN 
    1. GTY1229666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Check the fitting condition between the piston and piston pin.
        1. Try to move the piston back and forth on the piston pin.

        HINT: 

        If abnormal movement is felt, replace the piston and piston pin as a set.

      2. Remove the connecting rod from the piston.
        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).
      3. Gradually heat the piston to approximately 80°C (176°F).
        WARNING:

        Be sure to wear protective gloves.

      4. Using a brass bar and a hammer, lightly tap out the piston pin and 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.
    2. GTY1233709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a gasket scraper, remove any carbon from the piston top.
        NOTE:

        Be careful not to scratch the piston.

      2. Using a groove cleaning tool or a broken ring, clean the piston ring grooves.
      3. 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. GTY1231864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 5 mm hexagon socket wrench, remove the 3 bolts and 3 No. 1 oil nozzle sub-assemblies.
      2. Check the 3 No. 1 oil nozzle sub-assemblies for damage or clogging.
      3. If there is damage or clogs, replace the No. 1 oil nozzle sub-assembly.
  12. REMOVE CONNECTING ROD SMALL END BUSH 
    1. GTY1237864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST and a press, press out the connecting rod small end bush.
        • SST: 09222-30010 
  13. REMOVE STRAIGHT PIN 
    NOTE:

    It is not necessary to remove the straight pins unless they are being replaced.
    1. GTY1230669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE STUD BOLT 
    NOTE:

    If a stud bolt is deformed or its threads are damaged, replace it.
    1. GTY1228765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an E10 "TORX" socket wrench, remove the stud bolt from the cylinder block sub-assembly.
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