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Cylinder Block: Disassembly

  1. INSTALL ENGINE TO ENGINE STAND 
  2. REMOVE TIMING BELT AND PULLEYS (See  REMOVAL   ) 
  3. REMOVE CYLINDER HEAD (See  REMOVAL   ) 
  4. REMOVE RH ENGINE MOUNTING BRACKET 
  5. REMOVE LH ENGINE MOUNTING BRACKET 
  6. REMOVE STARTER (See  REMOVAL & INSTALLATION (GS430)  ) 
  7. REMOVE KNOCK SENSORS (See  KNOCK SENSOR  ) 
  8. REMOVE ENGINE WIRE 
    1. Disconnect the crankshaft position sensor connector.
    2. Remove the 2 bolts and engine wire cover from the LH side of the cylinder block.
      Fig 1: Removing Engine Wire Cover Bolts (LH)
      G02951546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts, and disconnect the engine wire from the RH side of the cylinder block.
      Fig 2: Removing Engine Wire Bolts (RH)
      G02951547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and engine wire.
  9. REMOVE WATER PUMP (See  REMOVAL  ) 
  10. REMOVE NO.2 OIL PAN (See  REMOVAL  ) 
  11. REMOVE OIL PAN BAFFLE PLATE 
  12. REMOVE NO.1 OIL PAN (See  REMOVAL  ) 
  13. REMOVE OIL STRAINER 
  14. REMOVE OIL PUMP (See  REMOVAL  ) 
  15. REMOVE WATER SEAL PLATE 

    Remove the 2 nuts and seal plate.

    Fig 3: Removing Water Seal Plate
    G02951548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE ENGINE COOLANT DRAIN UNIONS 

    Remove the RH and LH drain unions.

  17. REMOVE REAR OIL SEAL RETAINER 
    1. Remove the 7 bolts.
    2. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and main bearing cap.
    3. Remove the O-ring.
    Fig 4: Removing Rear Oil Seal Retainer Using Screwdriver
    G02951549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. CHECK CONNECTING ROD THRUST CLEARANCE 

    Using a dial indicator, measure the thrust clearance while moving the connecting rod back an forth.

    Standard thrust clearance: 0.160 - 0.290 mm (0.0063 - 0.0138 in.) 

    Maximum thrust clearance: 0.35 mm (0.0138 in.) 

    Fig 5: Measuring Thrust Clearance Moving Connecting Rod Using Dial Indicator
    G02951550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.

    Connecting rod thickness: 22.880 - 22.920 mm (0.9008 - 0.9024 in.) 

  19. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE 
    1. Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
      Fig 6: Checking Matchmarks On Connecting Rod And Cap
      G02951551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 connecting rod cap bolts.
      Fig 7: Removing Connecting Rod Cap Bolts
      G02951552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

      HINT:

      Keep the lower bearing inserted with the connecting rod cap.

    4. Clean the crank pin and bearing.
    5. 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.

    6. Lay a strip of Plastigage across the crank pin.
      Fig 8: Laying Plastigage Strip Across Crank Pin
      G02951553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the connecting rod cap with the 2 bolts (See REASSEMBLY  ).
      Fig 9: Installing Connecting Rod Cap Bolts
      G02951554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not turn the crankshaft.
    8. Remove the 2 bolts, connecting rod cap and lower bearing (See procedure  b and  c above).
    9. Measure the Plastigage at its widest point.

      Standard oil clearance: 0.021 - 0.047 mm (0.0008 - 0.0019 in.) 

      Maximum oil clearance: 0.065 mm (0.0026 in.) 

      If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.

      Fig 10: Measuring Plastigage
      G02951555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the connecting rod cap and crankshaft, then selecting the bearing with the same number as the total. There are 6 sizes of standard bearings, marked "2", "3", "4", "5", "6" and "7".

      Fig 11: Replacing Bearings
      G02951557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 12: Bearing Reference Chart
      G02951556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      EXAMPLE:

      Connecting rod cap "3" + Crankshaft "1"

      = Total number 4 (Use bearing "4")

      Reference 

      Connecting rod big end inside diameter: 

      CONNECTING ROD BIG END INSIDE DIAMETER SPECIFICATION

      Mark "1" 55.000 - 55.006 mm (2.1654 - 2.1656 in.)
      Mark "2" 55.006 - 55.012 mm (2.1656 - 2.1658 in.)
      Mark "3" 55.012 - 55.018 mm (2.1658 - 2.1661 in.)
      Mark "4" 55.018 - 55.024 mm (2.1661 - 2.1663 in.)

      Crankshaft crank pin diameter: 

      CRANKSHAFT CRANK PIN DIAMETER SPECIFICATION

      Mark "1" 51.994 - 52.000 mm (2.0470 - 2.0472 in.)
      Mark "2" 51.988 - 51.994 mm (2.0468 - 2.0470 in.)
      Mark "3" 51.982 - 51.988 mm (2.0465 - 2.0468 in.)

      Standard sized bearing center wall thickness: 

      BEARING CENTER WALL THICKNESS SPECIFICATION

      Mark "2" 1.487- 1.490 mm (0.0585 - 0.0587 in.)
      Mark "3" 1.490- 1.493 mm (0.0587 - 0.0588 in.)
      Mark "4" 1.493- 1.496 mm (0.0588 - 0.0589 in.)
      Mark "5" 1.496- 1.499 mm (0.0589 - 0.0590 in.)
      Mark "6" 1.499- 1.502 mm (0.0590 - 0.0591 in.)
      Mark "7" 1.502- 1.505 mm (0.0591 - 0.0593 in.)
    10. Completely remove the Plastigage.
  20. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES 
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
      Fig 13: Removing Carbon From Top Of Cylinder Using Ridge Reamer
      G02951558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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 correct order.
  21. CHECK CRANKSHAFT THRUST CLEARANCE 

    Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

    Standard thrust clearance: 0.020 - 0.220 mm (0.0008 - 0.0087 in.) 

    Maximum thrust clearance: 0.30 mm (0.0118 in.) 

    Fig 14: Measuring Thrust Clearance Prying Crankshaft Back And Forth With Screwdriver
    G02951559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    If the thrust clearance is greater than maximum, replace the thrust washers as a set.

    Thrust washer thickness: 

    2.440 - 2.490 mm (0.0961 - 0.0980 in.) 

  22. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE 
    1. Remove the 10 main bearing cap bolts.
      Fig 15: Removing Main Bearing Caps Bolts
      G02951560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Uniformly loosen and remove the 20 main bearing cap bolts in several passes, in the sequence shown in Fig 16.
      Fig 16: Removing Main Bearing Cap Bolts In Sequence
      G02951561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using 2 screwdrivers, pry out the main bearing cap, and remove the 5 main bearing caps, 5 lower bearings and 2 lower thrust washers (No.3 main bearing cap only).
      Fig 17: Prying Main Bearing Cap Using Screwdriver
      G02951562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage the cylinder block.

      HINT:

      • Keep the lower bearing and main bearing cap together.
      • Arrange the main bearing caps and lower thrust washers in correct order.
    4. Lift out the crankshaft.
    5. Remove the 2 upper thrust washers.

      HINT:

      • Arrange the upper thrust washers in correct order.
      • Keep the upper bearings together with the cylinder block.
    6. Clean each main journal and bearing.
    7. Check each main journal and bearing for pitting and scratches.

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

    8. Install the 10 main bearings and 5 main bearing caps with the 30 bolts. Do not install the crankshaft (See REASSEMBLY  ).
      Fig 18: Installing Main Bearing And Bearing Caps Bolts
      G02951563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using a cylinder gauge, measure the inside diameter of the main bearing.

      Bearing inside diameter: 

      66.986 - 67.000 mm (2.6372 - 2.6378 in.) 

      Fig 19: Measuring Inside Diameter Of Main Bearing Using Cylinder Gauge
      G02951564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Measure the diameter of the main journal (See INSPECTION  )
    11. Subtract the main journal diameter measurement from the main bearing inside diameter measurement.

      Standard clearance: 

      MAIN BEARING STANDARD CLEARANCE SPECIFICATION

      No.1 and No.5 0.017 - 0.033 mm (0.0007 - 0.0013 in.)
      Others 0.029 - 0.045 mm (0.0011 - 0.0018 in.)

      Maximum clearance: 

      MAIN BEARING MAXIMUM CLEARANCE SPECIFICATION

      No.1 and No.5 0.043 mm (0.0017 in.)
      Others 0.055 mm (0.0022 in.)

      If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft.

      HINT:

      If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of the standard bearings. For No.1 and No.5 position bearings, use bearings marked "3", "4", "5", "6" and "7". For others position bearings, use bearings marked "1", "2", "3", "4" and "5".

      Fig 20: Marking Main Journal
      G02951565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 21: Main Bearing Reference Table (No.1, No.5)
      G02951566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      EXAMPLE:

      Cylinder block "08" + Crankshaft "06"

      = Total number 14 (Use bearing "4" (Upper), "5" (Lower))

      Fig 22: Main Bearing Reference Table (Others)
      G02951567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      EXAMPLE:

      Cylinder block "08" + Crankshaft "06"

      = Total number 14 (Use bearing "2" (Upper), "3" (Lower))

      Reference 

      Cylinder block main journal bore diameter (A): 

      CYLINDER BLOCK MAIN JOURNAL BORE DIAMETER (A) SPECIFICATION

      Mark "00" 72.000 mm (2.8346 in.)
      Mark "01" 72.001 mm (2.8347 in.)
      Mark "02" 72.002 mm (2.8347 in.)
      Mark "03" 72.003 mm (2.8348 in.)
      Mark "04" 72.004 mm (2.8348 in.)
      Mark "05" 72.005 mm (2.8348 in.)
      Mark "06" 72.006 mm (2.8349 in.)
      Mark "07" 72.007 mm (2.8349 in.)
      Mark "08" 72.008 mm (2.8350 in.)
      Mark "09" 72.009 mm (2.8350 in.)
      Mark "10" 72.010 mm (2.8350 in.)
      Mark "11" 72.011 mm (2.8351 in.)
      Mark "12" 72.012 mm (2.8351 in.)
      Mark "13" 72.013 mm (2.8352 in.)
      Mark "14" 72.014 mm (2.8352 in.)
      Mark "15" 72.015 mm (2.8352 in.)
      Mark "16" 72.016 mm (2.8353 in.)

      Crankshaft main journal diameter (B): 

      CRANKSHAFT MAIN JOURNAL DIAMETER (B) SPECIFICATION

      Mark "00" 67.000 mm (2.6378 in.)
      Mark "01" 66.999 mm (2.6378 in.)
      Mark "02" 66.998 mm (2.6377 in.)
      Mark "03" 66.997 mm (2.6377 in.)
      Mark "04" 66.996 mm (2.6376 in.)
      Mark "05" 66.995 mm (2.6376 in.)
      Mark "06" 66.994 mm (2.6376 in.)
      Mark "07" 66.993 mm (2.6375 in.)
      Mark "08" 66.992 mm (2.6375 in.)
      Mark "09" 66.991 mm (2.6374 in.)
      Mark "10" 66.990 mm (2.6374 in.)
      Mark "11" 66.989 mm (2.6374 in.)
      Mark "12" 66.988 mm (2.6373 in.)

      Standard bearing center wall thickness: 

      No.1 and No.5 

      STANDARD BEARING CENTER WALL THICKNESS (NO.1 AND NO.5) SPECIFICATION

      Mark "3" 2.492 - 2.495 mm (0.0981 - 0.0982 in.)
      Mark "4" 2.495 - 2.498 mm (0.0982 - 0.0983 in.)
      Mark "5" 2.498 - 2.501 mm (0.0983 - 0.0985 in.)
      Mark "6" 2.501 - 2.504 mm (0.0985 - 0.0986 in.)
      Mark "7" 2.504 - 2.507 mm (0.0986 - 0.0987 in.)

      Others: 

      OTHER BEARING SPECIFICATION

      Mark "1" 2.486 - 2.489 mm (0.0979 - 0.0980 in.)
      Mark "2" 2.489 - 2.492 mm (0.0980 - 0.0981 in.)
      Mark "3" 2.492 - 2.495 mm (0.0981 - 0.0982 in.)
      Mark "4" 2.495 - 2.498 mm (0.0982 - 0.0983 in.)
      Mark "5" 2.498 - 2.501 mm (0.0983 - 0.0985 in.)
    12. Remove the 10 bolts, 20 nuts, 5 main bearing caps and 5 lower main bearing. (See procedure  a to  c above)
      Fig 23: Removing Main Bearing Caps Bolts
      G02951568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Remove the 5 upper main bearings from the cylinder block.

    HINT:

    Arrange the main bearing caps, bearings and thrust washers in correct order.

  23. CHECK FIT BETWEEN PISTON AND PISTON PIN 

    Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.

    Fig 24: Checking Fit Between Piston And Piston Pin
    G02951569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE PISTON RINGS 
    1. Using a piston ring expander, remove the 2 compression rings.
      2. Fig 25: Removing Compression Rings Using Piston Ring Expander
      G02951570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 side rails and oil ring by hand.

    HINT:

    Arrange the piston rings in correct order only.

  25. DISCONNECT CONNECTING ROD FROM PISTON 
    1. Using a small screwdriver, pry out the 2 snap rings.
      Fig 26: Prying Snap Ring
      G02951571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Gradually heat the piston to approx. 60°C (140°F).
      Fig 27: Heating Pistons
      G02951572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and pin and remove the connecting rod.
      Fig 28: Tapping Piston Pin, Pin And Removing Connecting Rod
      G02951573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    • The piston and pin are a matched set.
    • Arrange the pistons, pins, rings, connecting rods and bearings in correct order.
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