Cylinder Block: Disassembly

1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

   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.

   Fig 1: Measuring Connecting Rod Thrust Clearance

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1. Check the alignment marks on the connecting rod and cap to ensure correct reassembly.
   Fig 2: Identifying Alignment Marks On Connecting Rod And Cap

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2. Remove the 2 bolts and connecting rod cap.

   HINT:

   Keep the lower bearing and connecting rod cap together.

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

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

   Fig 3: Locating Connecting Rod Cap Bolts

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5. Lay a strip of Plastigage on the crank pin.
   Fig 4: Laying Strip Of Plastigage On Crank Pin

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6. Check that the front mark of the connecting rod cap is facing in the correct direction.
   Fig 5: Identifying Front Mark Of Connecting Rod Cap

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7. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
8. Install and alternately tighten the bolts of the connecting rod cap in several steps.

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

   NOTE: Do not turn the crankshaft during the measurement.

   If any one of the connecting rod bolts does not meet the torque specification, replace the connecting rod bolts.

   Fig 6: Locating Connecting Rod Cap Bolts

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9. Mark the front of each connecting rod bolt with paint.
10. Tighten the bolts 90° as shown in the illustration.
    NOTE: Do not turn the crankshaft during the measurement.
11. Remove the 2 bolts and connecting rod cap.

    HINT:

    Keep the lower bearing and connecting rod cap together.

    Fig 7: Identifying Connecting Rod Bolt Angle With Paint Mark

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12. Measure the Plastigage at its widest point.

    Standard oil clearance: 

    0.030 to 0.063 mm (0.00118 to 0.00248 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 bearing, select a new one with the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.

    Standard crank pin diameter: 

    51.492 to 51.500 mm (2.0272 to 2.0276 in.) 

    Fig 8: Measuring Plastigage At Widest Point

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Standard Connecting Rod Big End Inside Diameter 

    CONNECTING ROD BIG END INSIDE DIAMETER SPECIFICATION
    
    

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

    Standard Size Bearing Center Wall Thickness 

    SIZE BEARING CENTER WALL THICKNESS SPECIFICATION
    
    

    Item	Specified Condition
    Mark 1	1.483 to 1.487 mm (0.0584 to 0.0585 in.)
    Mark 2	1.488 to 1.491 mm (0.0586 to 0.0587 in.)
    Mark 3	1.492 to 1.495 mm (0.0587 to 0.0589 in.)

13. Perform the inspection above for each cylinder.

1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Remove the 8 bolts, 4 connecting rod caps and 4 lower bearings.
3. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

Fig 9: Removing Carbon From Top Of Cylinder

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HINT:

• Keep the bearings, connecting rod and cap together.
• Arrange the piston and connecting rod assemblies in the correct order.
• Be sure to arrange the removed piston and connecting rod assemblies in such a way that they can be reinstalled exactly as before.

1. Remove the connecting rod bearings from the connecting rods and connecting rod caps.

   HINT:

   Arrange the removed parts in the correct order.

1. Using a dial indicator, measure the 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.) 

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

   Fig 10: Measuring Crankshaft Thrust Clearance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard thrust washer thickness: 

   1.93 to 1.98 mm (0.0760 to 0.0780 in.) 

1. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
2. Remove the 5 bearing caps from the cylinder block.

   HINT:

   • Keep the No. 2 crankshaft bearings and crankshaft bearing caps together.
   • Arrange the bearing caps in the correct order.
   Fig 11: Identifying Bearing Cap Bolts Loosening Sequence

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3. Remove the crankshaft from the cylinder block.

   HINT:

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

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

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

1. Remove the thrust washers from the cylinder block.

1. Remove the crankshaft bearings from the cylinder block and bearing caps.

   HINT:

   Arrange the bearings in the correct order.

1. Using a screwdriver, remove the 2 pulley keys from the crankshaft.

Fig 12: Locating Crankshaft Bearing

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1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the oil ring and expander by hand.

   HINT:

   Arrange the removed parts in the correct order.

Fig 13: Removing Compression Rings

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1. Insert a small screwdriver into the service hole, pry out the snap ring on the front side.

Fig 14: Prying Out Snap Ring On Front Side

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1. Gradually heat the piston up to 80 to 90°C (176 to 194°F).
   Fig 15: Heating Piston

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2. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin. Then remove the connecting rod.

   HINT:

   • The piston and pin are a matched set.
   • Be sure to arrange the removed pistons, pins, rings, connecting rods and bearings in such a way that the parts can be reinstalled exactly as before.
   • Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
   Fig 16: Tapping Out Piston Pin

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1. Using a 5 mm hexagon wrench, remove the 2 bolts and 2 oil nozzles.

Fig 17: Locating Oil Nozzles Bolts

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1. Using a 5 mm hexagon wrench, remove the 4 bolts and 4 oil nozzles.