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Disassembly [11/2016 - ]: Procedure

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  1. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    1. Remove the cylinder block water jacket spacer and cylinder block water jacket spacer LH from the cylinder block sub-assembly.
      GTY629226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD 
    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.
      GTY668169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Front of Engine
    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.
      GTY653620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Keep the lower connecting rod bearing installed to the connecting rod cap.

    4. Using a ridge reamer, remove all of the carbon from the top of the cylinder.
      GTY623283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Ridge Reamer
    5. 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.
  3. REMOVE CONNECTING ROD BEARING 
    1. Remove the connecting rod bearings from the connecting rod sub-assembly and connecting rod cap.

      HINT: 

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

  4. REMOVE PISTON RING SET 
    1. Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring.
      GTY673355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Piston Ring Expander
    2. Remove the oil ring expander and 2 side rails by hand.

      HINT: 

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

  5. REMOVE PISTON 
    1. Check the fitting condition between the piston and piston pin.
      GTY653613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 sub-assembly from the piston.
      GTY653614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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).
      2. Gradually heat the piston to approximately 80°C (176°F).
        GTY579103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        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 sub-assembly.
        GTY579102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        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.
    3. Using a gasket scraper, remove any carbon from the piston top.
      GTY653623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to scratch the piston.

    4. Using a groove cleaning tool or a broken ring, clean the piston ring grooves.
      GTY681548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using solvent and a brush, thoroughly clean the piston.
      GTY653559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not use a wire brush.

  6. REMOVE CRANKSHAFT 
    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.
      Fig 1: Crankshaft Bearing Caps Bolt Loosening Sequence (1 Of 2)
      GTY656600Courtesy 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 Caps Bolt Loosening Sequence (2 Of 2)
      GTY649564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver with its tip wrapped with protective tape, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and lower crankshaft bearings as a set.
      GTY645358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cylinder Block Sub-assembly
      *2 Crankshaft Bearing Cap
      *a Protective Tape
      *b Contact Surface
      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.
    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.
      GTY653019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon socket wrench, remove the 3 bolts and 3 No. 1 oil nozzle sub-assemblies.
      GTY653022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the 3 No. 1 oil nozzle sub-assemblies for damage or clogging.

      HINT: 

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

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