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Disassembly [12/2013 - 11/2016]: Procedure

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  1. 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 cap bolts.
      GTY437127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Engine Front
    3. Using the 2 removed connecting rod cap 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 into the connecting rod cap.

    4. Using a ridge reamer, remove all of the carbon from the top of the cylinder.
      GTY437402Courtesy 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 the correct order.
  2. REMOVE CONNECTING ROD BEARING 

    HINT: 

    Arrange the removed parts in the correct order.

  3. REMOVE PISTON RING SET 
    1. Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring.
      GTY434264Courtesy 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 the correct order.

  4. REMOVE PISTON 
    1. Check the fitting condition between the piston and piston pin.
      GTY100969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Try to move the piston back and forth on the piston pin.

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

    2. Remove the connecting rod sub-assembly from the piston.
      GTY124214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver, pry off the piston pin hole snap rings from the piston.
      2. Gradually heat the piston to approximately 80°C (176°F).
        GTY161610Courtesy 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.
        GTY174255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT: 

        • The piston and piston pin are a matched set.
        • Arrange the removed parts in the correct order.
    3. Using a gasket scraper, remove any carbon from the piston top.
      GTY124215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to scratch a piston.

    4. Using a groove cleaning tool or a broken ring, clean the piston ring grooves.
      GTY146531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using solvent and a brush, thoroughly clean the piston.
      GTY146532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not use a wire brush.

  5. 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: Loosening Sequence Of 8 Crankshaft Bearing Cap Set Bolts
      GTY440517Courtesy 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: Loosening Sequence Of 16 Crankshaft Bearing Cap Set Bolts
      GTY438841Courtesy 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.
      GTY450285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Cylinder Block Sub-Assembly
      *2 Crankshaft Bearing Cap
      *a Protective Tape
      *b Joint Surface
      NOTE:
      • Push up 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 contact surfaces of the cylinder block sub-assembly and the crankshaft bearing cap.

      HINT: 

      Tape the screwdriver tip before use.

    4. Remove the crankshaft.
  6. REMOVE CRANKSHAFT BEARING 
    1. Remove the upper crankshaft bearings and lower crankshaft bearings.

      HINT: 

      Arrange the removed parts in the correct order.

  7. REMOVE CRANKSHAFT THRUST WASHER SET 
    1. Remove the crankshaft thrust washer set from the cylinder block sub-assembly.
      GTY145649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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.
      GTY293631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the 3 No. 1 oil nozzle sub-assemblies for damage or clogging.

      If necessary, replace the No. 1 oil nozzle sub-assembly.

  9. CLEAN CYLINDER BLOCK SUB-ASSEMBLY 
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