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Home >> Toyota >> 2016 >> Corolla S, Standard Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Engine Mechanical (2ZR-FAE) - Service Information (2 Of 2) (Model Code: ZRE172)) >> Cylinder Block >> Disassembly [08/2013 - ] >> Procedure

Disassembly [08/2013 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE NO. 1 VENTILATION CASE 
    1. Remove the 6 bolts and 2 nuts.
      GTY449227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block sub-assembly as shown in the illustration.
      GTY443301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

      Be careful not to damage the contact surfaces of the cylinder block sub-assembly and No. 1 ventilation case.

      HINT: 

      Tape the screwdriver tip before use.

  2. INSPECT CONNECTING ROD THRUST CLEARANCE 
    1. Using a dial indicator, measure the thrust clearance while moving the connecting rod cap back and forth.
      GTY228006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Thrust Clearance

      0.160 to 0.342 mm (0.00630 to 0.0135 in.)

      Maximum Thrust Clearance

      0.342 mm (0.0135 in.)

      If the thrust clearance is greater than the maximum, replace the connecting rod sub-assembly as necessary. If necessary, replace the crankshaft.

  3. INSPECT CONNECTING ROD OIL CLEARANCE 
    1. Check that the matchmarks on the connecting rod and connecting rod cap are aligned to ensure correct reassembly.
      GTY436690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark

      HINT: 

      The matchmarks on the connecting rods and connecting rod caps are provided to ensure correct reassembly.

    2. Using SST, uniformly loosen the 2 connecting rod bolts.
      • SST: 09205-16011 
      GTY432766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using the 2 removed connecting rod bolts, remove the connecting rod cap and crankshaft bearing by wiggling the connecting rod cap back and forth.
      GTY224263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Keep the crankshaft bearing inserted in 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.

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

    6. Lay a strip of Plastigage on the crank pin.
      GTY436459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
    7. Check that the front mark of the connecting rod cap is facing forward and install the connecting rod cap.
      GTY448848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark
    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:

      The connecting rod bolts should be tightened in 2 progressive steps.

    10. GTY432742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Step 1:

      1. Using SST, install and alternately tighten the connecting rod bolts of the connecting rod cap in several steps.
        • SST: 09205-16011 

        Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

        NOTE:

        Do not turn the crankshaft.

    11. Step 2:
      GTY438137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      Engine Front
      1. Mark the front of the connecting rod bolts with paint.
      2. Tighten the connecting rod bolts by 90° as shown in the illustration.
        NOTE:

        Do not turn the crankshaft.

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

      HINT: 

      Keep the crankshaft bearing inserted in the connecting rod cap.

    13. Measure the Plastigage at its widest point.
      GTY434300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
      *b 1, 2 or 3 Mark

      Standard Oil Clearance

      0.014 to 0.038 mm (0.000551 to 0.00150 in.)

      Maximum Oil Clearance

      0.070 mm (0.00276 in.)

      If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.

      NOTE:

      Remove the Plastigage completely after the measurement.

      HINT: 

      If replacing a connecting rod bearing, replace it with one that has the same number as its respective connecting rod cap. Each connecting rod bearing standard thickness is indicated by a 1, 2, or 3 mark on its surface.

      Standard Connecting Rod Large End Bore Diameter

      Mark Specified Condition
      1 47.000 to 47.008 mm (1.85039 to 1.85070 in.)
      2 47.009 to 47.016 mm (1.85074 to 1.85102 in.)
      3 47.017 to 47.024 mm (1.85106 to 1.85133 in.)

      Standard Connecting Rod Bearing Thickness

      Mark Specified Condition
      1 1.489 to 1.493 mm (0.05862 to 0.05878 in.)
      2 1.494 to 1.497 mm (0.05882 to 0.05894 in.)
      3 1.498 to 1.501 mm (0.05898 to 0.05909 in.)

      Standard Crankshaft Pin Diameter

      43.992 to 44.000 mm (1.7320 to 1.7323 in.)

    14. Perform the inspection above for each cylinder.
  4. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD 
    1. Using a ridge reamer, scrape off any carbon on the top of the cylinder.
      GTY161144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Push the piston, connecting rod and connecting rod bearing through the top of the cylinder block sub-assembly.

      HINT: 

      • Keep the connecting rod bearing, connecting rod and connecting rod cap together.
      • Arrange the pistons and connecting rods in the correct order.
      • Be sure to arrange the removed pistons and connecting rods in such a way that they can be reinstalled exactly as before.
  5. REMOVE CONNECTING ROD BEARING 
    1. Remove the connecting rod bearings.

      HINT: 

      Arrange the removed parts in the correct order.

  6. REMOVE PISTON RING SET 
    1. Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring.
      GTY230490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for 2-piece Type:
      1. Remove the oil ring and oil ring expander by hand.

        HINT: 

        Arrange the removed parts in the correct order.

    3. for 3-piece Type:
      1. Remove the oil ring expander, upper side rail and lower side rail by hand.

        HINT: 

        Arrange the removed parts in the correct order.

  7. REMOVE PISTON 
    1. Using a screwdriver, pry out the 2 piston pin hole snap rings.
      GTY164432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Gradually heat each piston to approximately 80 to 90°C (176 to 194°F).
      GTY161610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.
      GTY162022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      • The piston and piston pin are a matched set.
      • Arrange the pistons, piston pins, piston rings, connecting rods and connecting rod bearings in the correct order.
  8. INSPECT CRANKSHAFT THRUST CLEARANCE 
    1. Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.
      GTY234991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Thrust Clearance

      0.04 to 0.14 mm (0.00157 to 0.00551 in.)

      Maximum Thrust Clearance

      0.18 mm (0.00709 in.)

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

      HINT: 

      The upper crankshaft thrust washer thickness is 2.43 to 2.48 mm (0.0957 to 0.0976 in.).

  9. REMOVE CRANKSHAFT 
    1. Uniformly loosen and remove the 10 crankshaft bearing cap set bolts in the order shown in the illustration.
      Fig 1: Crankshaft Bearing Cap Bolts Loosening Sequence
      GTY430217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using the 2 removed crankshaft bearing cap set bolts, remove the 5 crankshaft bearing caps and 5 crankshaft bearings.
      GTY224238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Insert the crankshaft bearing cap set bolts into the caps in turn. Ease the crankshaft bearing cap out by gently pulling up while applying force toward the front and back sides of the cylinder block sub-assembly as shown in the illustration. Take care not to damage the contact surfaces of the crankshaft bearing cap and cylinder block sub-assembly.

      HINT: 

      • Keep the crankshaft bearing and crankshaft bearing cap together as a set.
      • Arrange the crankshaft bearing caps in the correct order.
    3. Lift out the crankshaft.
    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.

  10. REMOVE UPPER CRANKSHAFT THRUST WASHER 
    1. Remove the 2 upper crankshaft thrust washers from the cylinder block sub-assembly.
      GTY164439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE CRANKSHAFT BEARING 
    1. Remove the 5 crankshaft bearings from the cylinder block sub-assembly.
      GTY161259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Arrange the crankshaft bearings in the correct order.

    2. Remove the 5 crankshaft bearings from the 5 crankshaft bearing caps.
      GTY164440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Arrange the removed parts in the correct order.

  12. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm socket hexagon wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies.
      GTY455414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. CLEAN CYLINDER BLOCK SUB-ASSEMBLY 
    NOTE:

    If the cylinder is washed at high temperatures, the cylinder liner will stick out beyond the cylinder block sub-assembly. Always wash the cylinder block sub-assembly at a temperature of 45°C (113°F) or less.

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