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Disassembly [11/2022 - 09/2024]: Procedure

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  1. REMOVE NO. 1 VENTILATION CASE 
    WARNING:

    Do not disassembly except if the No. 1 ventilation case to be damaged.

    1. Remove the 3 bolts, 2 nuts and No. 1 ventilation case from the cylinder block sub-assembly.
      GTY1019445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 oil separator gaskets from the No. 1 ventilation case.
      GTY1019443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE NO. 1 CYLINDER BLOCK INSULATOR 
    1. Remove the No. 1 cylinder block insulator from the cylinder block sub-assembly.
      GTY1020382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT CONNECTING ROD THRUST CLEARANCE 
    1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
      GTY1019330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Thrust Clearance

      0.160 to 0.512 mm (0.00630 to 0.02016 in.)

      Maximum Thrust Clearance

      0.512 mm (0.02016 in.)

      HINT: 

      If the thrust clearance is more than the maximum, replace the connecting rod. If necessary, replace the crankshaft.

  4. INSPECT CONNECTING ROD OIL CLEARANCE 
    1. Note the alignment marks on the connecting rod and connecting rod bearing cap so that they can be reinstalled to their original locations.
      GTY1020128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark
    2. Using an E12 TORX socket wrench, remove the 2 connecting rod bolts and connecting rod bearing cap.
      GTY1019431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09205-16011 

      HINT: 

      Keep the connecting rod bearing and connecting rod bearing cap together.

    3. Clean the crank pin and connecting rod bearing.
    4. Check the crank pin and connecting rod bearing for pitting and scratches.

      HINT: 

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

    5. Lay a strip of Plastigage on the crank pin.
      GTY1019758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
    6. Check that the front mark of the connecting rod bearing cap is facing the correct direction, and install the connecting rod bearing cap to the connecting rod.
      GTY1019635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark
    7. Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.
      GTY1019347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using an E12 TORX socket wrench, install and alternately tighten the 2 connecting rod bolts in several steps.
      • SST: 09205-16011 

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

    9. Mark the front of each connecting rod bolt with paint.
      GTY1019987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b 90°
      Front of Engine
    10. Tighten the connecting rod bolts 90° as shown in the illustration.
      NOTE:

      Do not turn the crankshaft during the measurement.

    11. Remove the 2 connecting rod bolts and connecting rod bearing cap.

      HINT: 

      Keep the connecting rod bearing and connecting rod bearing cap together.

    12. Measure the Plastigage at its widest point.
      GTY1019554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
      *b 1, 2 or 3 Mark

      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 the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, replace the crankshaft.
      • If replacing a connecting rod bearing, select a new one with the same number as marked on the connecting rod bearing 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 51.000 to 51.008 mm (2.00787 to 2.00818 in.)
      2 51.008 to 51.016 mm (2.00818 to 2.00850 in.)
      3 51.016 to 51.024 mm (2.00850 to 2.00881 in.)

      Standard Connecting Rod Bearing Center Wall Thickness

      Mark Specified Condition
      1 1.487 to 1.491 mm (0.0585 to 0.0587 in.)
      2 1.491 to 1.495 mm (0.0587 to 0.0589 in.)
      3 1.495 to 1.499 mm (0.0589 to 0.0590 in.)

      Standard Crank Pin Diameter

      47.992 to 48.000 mm (1.88945 to 1.88976 in.)

      NOTE:

      Remove the Plastigage completely after the measurement.

    13. Perform the inspection above for each cylinder.
  5. REMOVE PISTON WITH CONNECTING ROD 
    1. Using a ridge reamer, remove all the carbon from the top of each cylinder.
    2. Remove the 6 connecting rod bolts, 3 connecting rod bearing caps and 3 connecting rod bearings.
    3. Push the 3 pistons, 3 connecting rods and 3 connecting rod bearings out through the top of the cylinder block sub-assembly.

      HINT: 

      • Keep the connecting rod bearings, connecting rods and connecting rod bearing caps together.
      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.
  6. REMOVE CONNECTING ROD BEARING 
    1. Remove the 6 connecting rod bearings from the 3 connecting rods and 3 connecting rod bearing caps.

      HINT: 

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

  7. INSPECT CRANKSHAFT THRUST CLEARANCE 
    1. Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.
      GTY1020366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Thrust Clearance

      0.02 to 0.22 mm (0.000787 to 0.00866 in.)

      Maximum Thrust Clearance

      0.22 mm (0.00866 in.)

      HINT: 

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

      Standard Thrust Washer Thickness

      2.415 to 2.465 mm (0.0951 to 0.0970 in.)

  8. REMOVE CRANKSHAFT 
    1. Uniformly loosen and remove the 8 crankshaft bearing cap set bolts and 10 bolts.
      GTY1019434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the crankshaft bearing cap from the cylinder block sub-assembly with a screwdriver with its tip wrapped with protective tape.

      HINT: 

      • Keep the No. 2 crankshaft bearings and crankshaft bearing caps together.
      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.
      GTY1019381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the crankshaft from the cylinder block sub-assembly.

      HINT: 

      Keep the crankshaft bearings and crankshaft thrust washers together with the cylinder block sub-assembly.

    4. Check each crankshaft journal and crankshaft bearing for pitting and scratches.

      HINT: 

      If the journal or crankshaft bearing is damaged, replace the crankshaft bearings. If necessary, replace the crankshaft.

  9. REMOVE CRANKSHAFT THRUST WASHER 
    1. Remove the 2 crankshaft thrust washers from the No. 3 journal position of the cylinder block sub-assembly.
      GTY1019383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE CRANKSHAFT BEARING 
    1. Remove the 4 No. 1 crankshaft bearings and 4 No. 2 crankshaft bearings from the cylinder block sub-assembly and crankshaft bearing cap.

      HINT: 

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

  11. REMOVE PISTON RING SET 
    1. Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring from the piston.
      GTY768197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Piston Ring Expander
    2. Remove the oil ring expander, upper side rail and lower side rail from the piston by hand.

      HINT: 

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

  12. REMOVE PISTON PIN HOLE SNAP RING 
    1. Using a screwdriver, pry out the 2 piston pin hole snap rings from the piston.
      GTY791236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark Cutout Portion
      *b Protective Tape

      HINT: 

      Tape the screwdriver tip before use.

  13. REMOVE PISTON 
    1. Gradually heat each piston to between 80 and 90°C (176 and 194°F).
      GTY757106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      WARNING:

      Be sure to wear protective gloves.

    2. Using a brass bar and a hammer, lightly tap out the piston pin and remove the connecting rod.
      GTY757100Courtesy 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.
  14. 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 from the cylinder block sub-assembly.
      GTY1020370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon wrench, remove the 3 bolts and 3 No. 2 oil nozzle sub-assemblies from the cylinder block sub-assembly.
      GTY1019378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE NO. 3 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon wrench, remove the 3 bolts and 3 No. 3 oil nozzle sub-assemblies from the cylinder block sub-assembly.
      GTY1019385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE STUD BOLT 
    NOTE:

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

    1. Using an E8 "TORX" socket wrench, remove the 7 stud bolts.
      GTY1109204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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