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Disassembly [11/2023 - ]: Procedure

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  1. INSPECT CONNECTING ROD THRUST CLEARANCE 
    1. GTY1108981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a dial indicator, measure the thrust clearance while moving the connecting rod sub-assembly back and forth.

        Standard Thrust Clearance

        0.16 to 0.51 mm (0.00630 to 0.0201 in.)

        Maximum Thrust Clearance

        0.512 mm (0.0202 in.)

      2. 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. GTY1105413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark - -
      1. Note the alignment marks on the connecting rod and connecting rod cap so that they can be reinstalled to their original locations.
      2. Using an E12 "TORX" socket wrench, remove the 2 connecting rod bolts, then remove the connecting rod cap and connecting rod bearing together as a set.
      3. Clean the crank pin and connecting rod bearing and check the crank pin and connecting rod bearing for pitting and scratches.
        NOTE:

        Check that there is no significant wear or any scratches.

    2. GTY1104417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage *b Front Mark
      *c Paint Mark *d 90°
      *e Front of Engine *f 1, 2 or 3 Mark
      1. Lay a strip of Plastigage on the crank pin.
      2. Check that the front mark of the connecting rod cap is facing the correct direction, and install the connecting rod cap to the connecting rod.
      3. Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.
      4. Using an E12 "TORX" socket wrench, install and alternately tighten the 2 connecting rod bolts in several steps.

        Torque: 38 N.m (387 kgf/cm, 28 ft.lbf) 

      5. Mark the front of each connecting rod bolt with paint.
      6. Tighten the connecting rod bolts 90° as shown in the illustration.
        NOTE:

        Do not turn the crankshaft during the measurement.

      7. Confirm that the paint mark of every bolt has been turned 90°.
      8. Using an E12 "TORX" socket wrench, remove the 2 connecting rod bolts and connecting rod cap.
      9. Measure the Plastigage at its widest point.

        Standard Oil Clearance

        0.035 to 0.067 mm (0.00138 to 0.00264 in.)

        Maximum Oil Clearance

        0.067 mm (0.00264 in.)

        HINT: 

        If replacing a connecting rod bearing, select a new one with the same number as marked on the connecting rod cap. There are 3 sizes of standard connecting rod bearings, marked "1", "2" or "3" accordingly.

        Standard Connecting Rod Big End Inside Diameter

        Mark Specified Condition
        1 54.000 to 54.008 mm (2.12598 to 2.12629 in.)
        2 54.009 to 54.016 mm (2.12633 to 2.12661 in.)
        3 54.017 to 54.024 mm (2.12665 to 2.12692 in.)

        Standard Connecting Rod Bearing Center Wall Thickness

        Mark Specified Condition
        1 1.491 to 1.495 mm (0.05870 to 0.05886 in.)
        2 1.496 to 1.499 mm (0.05890 to 0.05902 in.)
        3 1.500 to 1.503 mm (0.05906 to 0.05917 in.)

        Standard Crank Pin Diameter

        50.992 to 51.000 mm (2.00756 to 2.00787 in.)

        NOTE:

        Remove the Plastigage completely after the measurement.

      10. If the oil clearance is more than the maximum, replace the connecting rod bearings.
      11. Perform the inspection above for each cylinder.
  3. REMOVE PISTON WITH CONNECTING ROD 
    1. GTY1104659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Ridge Reamer - -
      1. Using a ridge reamer, remove all the carbon from the top of each cylinder.
    2. GTY1076722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE CONNECTING ROD BEARING 
    1. GTY1076723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT CRANKSHAFT THRUST CLEARANCE 
    1. GTY1105478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a dial indicator, measure the crankshaft 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

        0.24 mm (0.00945 in.)

        Standard Crankshaft Thrust Washer Upper Thickness

        2.43 to 2.48 mm (0.0957 to 0.0976 in.)

      2. If the thrust clearance is more than the maximum, replace the crankshaft thrust washer uppers as a set. If necessary, replace the crankshaft.
  6. REMOVE CRANKSHAFT BEARING CAP 
    1. GTY1105470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Uniformly loosen and remove the 10 crankshaft bearing cap set bolts and 8 bolts in several steps in the order shown in the illustration.
      2. Using a screwdriver with its tip wrapped with protective tap, pry at the areas shown in the illustration to remove the crankshaft bearing cap and crankshaft bearings together as a set.
        NOTE:

        Be careful not to damage the contact surfaces of the cylinder block sub-assembly and crankshaft bearing cap.

  7. REMOVE CRANKSHAFT 
    1. GTY1076738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE CRANKSHAFT THRUST WASHER UPPER 
    1. GTY1076734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE CRANKSHAFT BEARING 
    1. GTY1077493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE PISTON RING SET 
    1. GTY1106382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Piston Ring Expander - -
      1. Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring from the piston.
      2. Remove the oil ring expander, upper side rail and lower side rail from the piston by hand.
  11. REMOVE PISTON PIN 
    1. GTY1108788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark Cutout Portion - -
      1. Using a screwdriver with its tip wrapped with protective tape, pry out the piston pin hole snap ring (front side) from the piston.
        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 each piston to between 80 and 90°C (176 and 194°F).
        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.
  12. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. GTY1103749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 5 mm hexagon socket wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies from the cylinder block sub-assembly.
  13. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY 
    1. GTY1107764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 5 mm hexagon socket wrench, remove the 4 bolts and 4 No. 2 oil nozzle sub-assemblies from the cylinder block sub-assembly.
  14. REMOVE RING PIN 
    NOTE:

    It is not necessary to remove the ring pins unless they are being replaced.

    1. GTY1077391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE STRAIGHT PIN 
    NOTE:

    It is not necessary to remove the straight pins unless they are being replaced.

    1. GTY1076238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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