LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2024 >> Corolla LE >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 93 (Engine Mechanical System (2ZR-FXE) - Service Information (3 Of 3)) >> Cylinder Block >> Disassembly [09/2024 - ] >> Procedure

Disassembly [09/2024 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    1. Remove the 2 cylinder block water jacket spacers from the cylinder block sub-assembly.
      GTY597993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE NO. 1 VENTILATION CASE 
    WARNING:

    When the No. 1 ventilation case is fastened using the bolt (A):

    Do not remove and install the No. 1 ventilation case.

    GTY1251309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Bolt (A)
    1. except Bolt (A):

      HINT: 

      There are 2 installation types for the No. 1 ventilation case.

      Depending on the installation type, the number of bolts, nuts and stud bolts used will vary.

      1. Type A:
        1. Remove the 6 bolts and 2 nuts.
          GTY909145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Type B:
        1. Remove the 8 bolts.
          GTY588251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block sub-assembly with a screwdriver with its tip wrapped with protective tape.
        GTY602750Courtesy 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.

  3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD 
    1. Place a paint mark across each corresponding connecting rod and connecting rod bearing cap.

      HINT: 

      The paint marks are used to ensure that the same parts are installed in the same combination to their original locations.

      GTY595528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
    2. Using SST, remove the 8 connecting rod bolts from the connecting rod bearing caps.
      • SST: 09205-16011 
      GTY586686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using the 2 removed connecting rod bolts, remove the 4 connecting rod caps with connecting rod bearings by wiggling each connecting rod cap left and right.

      HINT: 

      Keep the connecting rod bearing installed to the connecting rod cap.

      GTY608645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a ridge reamer, scrape off any carbon on the top of the cylinder.
      GTY161144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Push out the 4 pistons with 4 connecting rods and 4 connecting rod bearings through the top of the cylinder block sub-assembly.

      HINT: 

      • Keep the connecting rod bearings, connecting rods and connecting rod caps together.
      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.
  4. REMOVE CONNECTING ROD BEARING 
    1. Remove the 8 connecting rod bearings from the 4 connecting rods and 4 connecting rod caps.

      HINT: 

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

  5. REMOVE CRANKSHAFT 
    1. Uniformly loosen and remove the 10 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.
      GTY578153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using the 2 removed crankshaft bearing cap set bolts, remove the 5 crankshaft bearing caps from the cylinder block sub-assembly by wiggling each crankshaft bearing cap back and forth.

      HINT: 

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

      GTY588285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the crankshaft from the cylinder block sub-assembly.
  6. REMOVE CRANKSHAFT BEARING 
    1. Remove the 5 upper crankshaft bearings from the cylinder block sub-assembly.

      HINT: 

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

      GTY588279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 lower crankshaft bearings from the 5 crankshaft bearing caps.

      HINT: 

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

      GTY605476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE UPPER CRANKSHAFT THRUST WASHER 
    1. Remove the 2 upper crankshaft thrust washers from the cylinder block sub-assembly.
      GTY588284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE PISTON RING SET 
    1. Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring from the piston.
      GTY608643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

  9. REMOVE PISTON 
    1. Using a screwdriver, pry out the piston pin hole snap ring from the piston.
      NOTE:
      • Do not remove the piston pin hole snap ring (rear side) unless it is being replaced.
      • Be careful not to damage the piston when removing the piston pin hole snap ring (rear side).
      GTY588264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Gradually heat the piston to approximately 80°C (176°F).
      WARNING:

      Be sure to wear protective gloves.

      GTY579103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and a hammer, lightly tap out the piston pin and remove the connecting rod.

      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.
      GTY579102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    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.
      GTY588278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals