Cylinder Block: Disassembly

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

   Standard thrust clearance: 

   0.15 to 0.55 mm (0.00591 to 0.0217 in.) 

   Maximum thrust clearance: 

   0.70 mm (0.0276 in.) 

   If the thrust clearance is greater than the maximum, replace one or more connecting rods as necessary.

   If necessary, replace the crankshaft.

   Fig 1: Measuring Connecting Rod Thrust Clearance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check that the front mark on the connecting rod and cap are aligned to ensure correct reassembly.
2. Remove the 2 connecting rod cap bolts.
   Fig 2: Removing Connecting Rod Cap Bolts

   Courtesy 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 to the connecting rod cap.

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

   Fig 3: Removing Connecting Rod Cap And Lower Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Clean the crank pin and bearing.
6. Lay a strip of Plastigage on the crank pin
   Fig 4: Laying Strip Of Plastigage On Crank Pin

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Check that the front mark of the connecting rod cap is facing forward.
   Fig 5: Identifying Front Mark Of Connecting Rod Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Install and alternately tighten the bolts of the connecting rod cap in several steps.

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

   NOTE: Do not turn the crankshaft.
   Fig 6: Tightening Connecting Rod Cap Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Mark the front side of each connecting rod cap bolt with paint.
10. Tighten the cap bolts 90° as shown in the illustration.
11. Check that the painted marks are now at a 90° angle to the front.
    NOTE: Do not turn the crankshaft.
12. Remove the 2 connecting rod cap bolts.
13. 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 to the connecting rod cap.

    Fig 7: Identifying Tightening Angle Of Connecting Rod Cap Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Measure the Plastigage at its widest point

    Standard oil clearance: 

    0.025 to 0.050 mm (0.000984 to 0.00197 in.) 

    Maximum oil clearance: 

    0.070 mm (0.00276 in.) 

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

    HINT:

    • If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap Each bearing's standard thickness is indicated by a 1, 2, 3 or 4 mark on its surface.
    • Select the correct bearing by adding together the number marks imprinted on the connecting rod big end and crank pin

      Example.

      Connecting rod "1" + Crank pin "2" = 3 (Use bearing "3")

    Reference.

    STANDARD SIZED BEARING CENTER WALL THICKNESS 

    STANDARD SIZED BEARING CENTER WALL THICKNESS SPECIFICATION
    
    

    Mark	Thickness
    2	1.489 to 1.492 mm (0.0586 to 0.0587 in.)
    3	1.492 to 1.495 mm (0.0587 to 0.0589 in.)
    4	1.495 to 1.498 mm (0.0589 to 0.0590 in.)
    5	1.498 to 1.501 mm (0.0590 to 0.0591 in.)
    6	1.501 to 1.504 mm (0.0591 to 0.0592 in.)
    7	1.504 to 1.507 mm (0.0592 to 0.0593 in.)

    CONNECTING ROD BIG END INSIDE DIAMETER 

    CONNECTING ROD BIG END INSIDE DIAMETER SPECIFICATION
    
    

    Mark	Thickness
    1	56.000 to 56 006 mm (2.20472 to 2.20496 in.)
    2	56.007 to 56.012 mm (2.20500 to 2.20520 in.)
    3	56.013 to 56.018 mm (2.20524 to 2.20543 in.)
    4	56.019 to 56.024 mm (2.20547 to 2.20567 in.)

    Fig 8: Measuring Plastigage

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    CRANKSHAFT PIN DIAMETER 

    CRANKSHAFT PIN DIAMETER SPECIFICATION
    
    

    Mark	Thickness
    1	52.995 to 53.000 mm (2.08642 to 2 08661 in.)
    2	52.989 to 52.994 mm (2.08618 to 2.08638 in.)
    3	52.982 to 52.988 mm (2.08591 to 2.08614 in.)

15. Completely remove the Plastigage.
16. Perform the inspection above for each cylinder.

1. Using a ridge reamer, remove all the carbon from the top of the cylinder
2. Remove the 16 cap bolts and 8 connecting rod caps.
3. Push the 8 pistons and 8 connecting rods through the top of the cylinder block

   HINT

   • Keep the bearing, connecting rod and cap together
   • Arrange the pistons and connecting rods in the correct order
     Fig 9: Removing Carbon From Top Of Cylinder

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the connecting rod bearings from the connecting rods and connecting rod caps

   HINT.

   Arrange the removed parts in the correct order

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

   Standard thrust clearance: 

   0.020 to 0.220 mm (0.000787 to 0.00876 in.) 

   Maximum thrust clearance: 

   0.30 mm (0.0118 in.) 

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

   Standard thrust washer thickness: 

   2.44 to 2.49 mm (0.0961 to 0.0980 in.) 

   Fig 10: Measuring Crankshaft Thrust Clearance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Uniformly loosen and remove the 10 bearing cap bolts and 10 seal washers in several steps, in the sequence shown in the illustration
   Fig 11: Identifying Loosening Sequence Of Bearing Cap Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Uniformly loosen the 20 bearing cap bolts in several steps, in the sequence shown in the illustration
   Fig 12: Identifying Loosening Sequence Of Bearing Cap Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, slightly pry up the 5 main bearing caps.
   NOTE:

   • Be careful not to damage the joint surface of the cylinder block and crankshaft bearing caps.
   • Pry up the left and right side of the cap little by little.

   HINT.

   Tape the screwdriver tip before use.

4. Using 2 inside position crankshaft bearing cap bolts, loosen each crankshaft bearing cap by moving it forward and backward, and remove each crankshaft bearing cap
5. Remove the crankshaft

1. Remove the crankshaft bearings from the bearing caps and cylinder block

   HINT.

   Arrange the removed parts in the correct order.

   Fig 13: Removing Main Bearing Caps

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the thrust washer set from the cylinder block and No. 3 bearing cap.
   Fig 14: Locating Crankshaft Thrust Washers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a 5 mm hexagon wrench, remove the 4 bolts and 4 oil nozzles
   Fig 15: Locating Oil Nozzle Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Arrange the piston rings in the correct order

1. Using a piston ring expander, remove the 2 compression rings
2. Using a piston ring expander, remove the oil ring.
3. Remove the oil ring expander by hand.
   Fig 16: Removing Piston Ring Set

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the connecting rod from the piston.
   1. Using a screwdriver, pry off the snap rings from the piston.
      Fig 17: Removing Snap Rings From Piston

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a brass bar and plastic-faced hammer, lightly tap out the piston pin and remove the connecting rod.

      HINT:

      • The piston and pin are a matched set.
      • Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
        Fig 18: Removing Piston Pin And Connecting Rod

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Clean the piston.
   1. Using a gasket scraper, remove the carbon from the piston top.
      Fig 19: Removing Carbon From Piston Top

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a groove cleaning tool or broken ring, clean the piston ring grooves
      Fig 20: Cleaning Piston Ring Grooves

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using solvent and a brush, thoroughly clean the piston.
      NOTE: Do not use a wire brush.