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Cylinder Block: Replacement

WARNING: This page is about a different car, the 2008 Lexus LS 600hL. However, it is still accessible from the selected car via links, so may be relevant.
  1. REPLACE CONNECTING ROD SMALL END BUSH 
    1. Using SST and a press, press out the bushing.

      SST 09222-30010 

      Fig 1: Removing Connecting Rod Small End Bush
      G05771507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Align the oil holes of a new bushing and the connecting rod.
      Fig 2: Identifying Oil Holes Of Bushing And Connecting Rod
      G05771508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, press in the bushing.

      SST 09222-30010 

      Fig 3: Installing Connecting Rod Small End Bush
      G05771507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a caliper gauge, measure the inside diameter of the connecting rod bush.

      STANDARD BUSH INSIDE DIAMETER 

      STANDARD BUSH INSIDE DIAMETER SPECIFICATION

      Mark Specified Condition
      A 22 005 to 22.008 mm (0.86633 to 0.86646 in.)
      B 22.009 to 22.011 mm (0.86650 to 0.86657 in.)
      C 22.012 to 22.014 mm (0.86661 to 0.86669 in.)
      Fig 4: Measuring Inside Diameter Of Connecting Rod Bush
      G04943536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT

      Make sure that the connecting rod mark and the bush's inside diameter match.

      If the result is not within the specified range, use a pin hole grinder to grind the bush's inside diameter so that it is within the specified range.

      If the mark is A but the measurement is within the specified range of mark B, replace the piston and pin set.

      If the mark is B but the measurement is within the specified range of mark C, replace the piston and pin set.

      Fig 5: [Grinding Bush's Inside Diameter]
      G05771511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Subtract the piston pin diameter measurement from the bush inside diameter measurement

      Standard oil clearance: 

      0.005 to 0.011 mm (0.000197 to 0.000433 in.) 

      Maximum oil clearance: 

      0.03 mm (0.00118 in.) 

    6. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb Check that the piston pin fits at normal room temperature
  2. REPLACE STRAIGHT PIN 
    NOTE: It is not necessary to remove the straight pin unless it is being replaced.
    1. Remove the straight pins.
      Fig 6: Pushing Piston Pin Into Connecting Rod
      G05771512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic-faced hammer, tap in new straight pins to the cylinder block.
      Fig 7: Identifying Straight Pins Dimensions
      G05771513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      STANDARD PROTRUSION 

      STRAIGHT PIN PROTRUSION SPECIFICATION

      Item Pin Diameter Specified Condition
      Pin A 10 mm (0.394 in) 23 mm (0.906 in.)
      Pin B 10 mm (0.394 in.) 11 mm (0.433 in)
      Pin C 8 mm (0.315 in.) 9 mm (0.354 in.)
      Pin D 4 mm (0.157 in.) 6 mm (0.236 in.)
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