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Home >> Toyota >> 2017 >> RAV4 XLE, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2AR-FE) (Service Information) (2 Of 2) (Except Hybrid) >> Cylinder Block >> Disassembly [12/2012 - 08/2014] >> Procedure

Disassembly [12/2012 - 08/2014]: Procedure

  1. INSPECT CONNECTING ROD THRUST CLEARANCE 
    1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
      GTY194919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

  2. INSPECT CONNECTING ROD OIL CLEARANCE 
    1. Check the alignment marks on the connecting rod and cap to ensure correct reassembly.
      GTY365466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Alignment Mark
    2. Remove the 2 bolts and connecting rod cap.
      GTY314674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

    5. Lay a strip of Plastigage on the crank pin.
      GTY383060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Plastigage
    6. Install the connecting rod cap.

      See step  11

      NOTE:

      Do not turn the crankshaft.

    7. Remove the 2 bolts and connecting rod cap.

      HINT: 

      Keep the lower bearing and connecting rod cap together.

    8. Measure the Plastigage at its widest point.
      GTY374959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Plastigage
      *2 Number Mark

      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 that which is 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.)

      Standard Connecting Rod Big End Inside Diameter

      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

      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.)
    9. Perform the inspection above for each cylinder.
  3. REMOVE PISTON WITH CONNECTING ROD 
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
      GTY174254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

      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.
  4. REMOVE CONNECTING ROD BEARING 
    1. Remove the connecting rod bearings from the connecting rods and connecting rod caps.

      HINT: 

      Arrange the removed parts in the correct order.

  5. INSPECT CRANKSHAFT THRUST CLEARANCE 
    1. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
      GTY194926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

      Standard thrust washer thickness

      1.93 to 1.98 mm (0.0760 to 0.0780 in.)

  6. REMOVE CRANKSHAFT 
    1. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
      Fig 1: Crankshaft Bearing Cap Bolts Loosening Sequence
      GTY374886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
    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.

  7. REMOVE CRANKSHAFT THRUST WASHER 
    1. Remove the thrust washers from the cylinder block.
      GTY170291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE CRANKSHAFT BEARING 
    1. Remove the crankshaft bearings from the cylinder block and bearing caps.

      HINT: 

      Arrange the bearings in the correct order.

  9. REMOVE CRANKSHAFT PULLEY KEY 
    1. Using a screwdriver, remove the 2 crankshaft pulley keys from the crankshaft.
  10. REMOVE PISTON RING SET 
    1. Using a piston ring expander, remove the 2 compression rings.
      GTY377098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Piston Ring Expander
    2. Remove the oil ring and expander by hand.

      HINT: 

      Arrange the removed parts in the correct order.

  11. REMOVE PISTON PIN HOLE SNAP RING 
    1. Insert a small screwdriver into the service hole and pry out the snap ring on the front side.
      GTY194925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not remove the snap ring on the rear side unless it is necessary. When the snap ring heeds to be removed, be careful not to damage the piston.

  12. REMOVE PISTON 
    1. Gradually heat the piston up to 80 to 90°C (176 to 194°F).
    2. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin. Then remove the connecting rod.
      GTY174255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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, piston pins, rings, connecting rods and bearings in the correct order.
  13. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon wrench, remove the 2 bolts and 2 No. 1 oil nozzle sub-assemblies.
      GTY312568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 2 oil nozzle sub-assemblies.
      GTY314616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE STUD BOLT 
    NOTE:

    If a stud bolt is deformed or its threads are damaged, replace it.

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