Disassembly Of Cylinder Block

1. REMOVE CLUTCH COVER AND DISC

2. REMOVE FLYWHEEL OR DRIVE PLATE AND REAR END PLATE

3. INSTALL ENGINE STAND FOR DISASSEMBLY

4. REMOVE CYLINDER HEAD ASSEMBLY

(a) Disconnect the No. 1 water by-pass hose from the water by-pass pipe.

(b) Disconnect the PCV hose from the cylinder block. (c> Remove the timing belt. (See pages EM-11 to 13)

(d) Remove the No. 2 timing belt cover.

(e) Remove the air intake chamber stay.

• w>

11

X-* \

V>ytn» * r.tt Vj4 10 13 11 7

— •

SST

»U'44J

(f) Using SST, remove the cylinder head bolts. SST 09043-38100

(g) Remove the cylinder head assembly.

6. REMOVE OIL FILTER

Using SST, remove the oil filter. SST 09228-44010

6. REMOVE OIL LEVEL GAUGE

7. REMOVE ALTERNATOR

8. REMOVE FUEL FILTER

9. REMOVE FUEL HOSE SUPPORT

10. REMOVE WATER BY-PASS PIPE

(a) Remove the two nuts from the timing belt case.

(b) Remove the three bolts from the cylinder block and remove the water by-pass pipe with gasket.

11. REMOVE OIL PAN (See page LU-6)

Toyota Teardown Timing Case

12. REMOVE TIMING BELT CASE WITH WATER PUMP

Remove the eight bolts and two nuts and remove the timing belt case and gaskets.

13. REMOVE REAR OIL SEAL RETAINER

Drive Shalt

14. REMOVE OIL PUMP DRIVE SHAFT

(a) Remove the bolt holding the oil pump drive shalt.

(b) While turning the oil pump drive shaft, slowly pull it out so as not to damage the bearing.

15. REMOVE OIL PUMP ASSEMBLY

(a) Remove the union bolt and nut and remove the oil pump outlet pipe.

(b) Remove bolt holding the oil pump, and remove the oil pump assembly.

Connecting Rod Thrust

16. MEASURE CONNECTING ROD THRUST CLEARANCE

Using a dial gauge, measure the thrust clearance. Standard clearance: 0.160 - 0.296 mm

(0.0063 - 0.0117 in.) Maximum clearance: 0.3 mm (0.012 In.)

If clearance is greater than maximum, replace the connecting rod and/or crankshaft.

17. REMOVE CONNECTING ROD CAPS AND MEASURE OIL CLEARANCE

(a) Using a punch or numbering stamp, mark the connecting rods and caps to ensure correct reassembly.

(b) Remove the rod caps.

ftf ItM

(c) Using a plastic-faced hammer, tap the rod bolts lightly and lift off the rod cap.

NOTE: Keep the bearing inserted with the cap.

(d) Clean the bearings and crankshaft pins.

(e) Inspect each bearing for pitting and radial scratches. If bearings are damaged, replace the bearings.

(f) Lay a strip of plastigage across the crankshaft pin.

(g) Align the rod and cap marks and fit on the cap. Torque the rod cap nuts.

NOTE: Do not turn the crankshaft.

(i) Measure the plastigage at its widest point.

Standard clearance: 0.021 — 0.053 mm

(0.0008 - 0.0021 in.) Maximum clearance: 0.08 mm (0.0031 In.)

If the clearance is greater than maximum, replace the bearings and/or grind the crank pins.

Under size bearing: U/S 0.25, 0.50

(j) Clean out any plastigage scraps from the bearing and crankshaft pin.

Front

NOTE: If replacing a standard size bearing with a standard oil clearance, replace with one having the same number. If the number of the bearing cannot be determined, select a bearing from the table below according to the numbers imprinted on the connecting rod cap and crankshaft.

Rod cap No. Crankshaft No.

0

i

2 0

2

2 1

3 0

2 2

3 1

3 2

Bearing No.

2

2

3

3

3

4

4

5

Example: Rod cap No. 2, Crankshaft No. 1 = Bearing No. 3

18. PUSH OUT PISTON AND CONNECTING ROD ASSEMBLY

(a) Remove all the carbon from top of the bore to the top of the cylinder.

(b) Cover the rod bolts with a short piece of hose to protect the crank pin from damage.

(c) Push the piston and connecting rod assembly out through the top of the cylinder block.

(d) Arrange the pistons and connecting rod caps in order.

19. MEASURE CRANKSHAFT THRUST CLEARANCE

Install a dial gauge and measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.

Standard clearance: 0.05 - 0.25 men

(0.0020 - 0.0098 in.) Maximum clearance: 0.3 mm (0.012 in.) Oversized thrust washer: 0/S 0.125. 0.25

20. REMOVE MAIN BEARING CAPS AND MEASURE OIL CLEARANCE

(a) Gradually loosen and remove the bearing cap bolts in three passes and in the numerical order shown.

(b) Using the removed bearing cap bolts, pry the bearing cap fore and aft, and remove it with the lower bearing and thrust washers (No. 4 journal only).

NOTE:

• Keep the lower bearing inserted with the cap.

• Arrange the caps and lower thrust washers in correct order.

(c) Lift off the crankshaft.

NOTE: Keep the upper bearings and upper thrust washers (for the No. 4 journal only) inserted in the cylinder block.

(d) Clean the journals and bearings.

(e) Check the journals and bearings for pitting and scratches.

If the journal or bearing is damaged, grind or replace the crankshaft and replace the bearing.

(f) Install the upper main bearing on the cylinder block and crankshaft.

(g) Lay a strip of plastigage across the main journals.

tuttii

(h) Install the main bearing caps. Torque the cap bolts. Torque: 1,040 kg cm (75 ft-lb, 102 N-m) NOTE: Do not turn crankshaft.

(i) Remove the main bearing caps.

(j) Measure the plastigauge at its widest point.

Standard clearance: 0.034 — 0.058 mm

(0.0013 - 0.0023 In.) Maximum clearance: 0.08 mm (0.0031 In.)

If the clearance is greater than maximum, replace the bearings and/or grind the main journals.

Undersized bearing: U/S 0.25, 0.50

NOTE: If replacing a standard size bearing with a standard oil clearance, replace with one having the same number. If the number of the bearing cannot be determined, select a bearing from the table below according to the numbers imprinted on the cylinder block and crankshaft.

Cylinder Block No.

1

2

I

3

2

3

Crankshaft No.

0

0

1

0

1 2

1

2

2

Bearing No.

1

2

2

3

3 J 3

4

4

5

Example: Cylinder Block No. 2, Crankshaft No. 1 » Bearing No. 3

21. REMOVE CRANKSHAFT

(a) Lift out the crankshaft.

(b) Remove the upper main bearings from the cylinder block.

(c) Clean out any plastigage scraps from the bearing and journals.

Journal

Journal

Front

ivam

INSPECTION OF CYLINDER BLOCK

1. REMOVE GASKET MATERIAL

Using a gasket scraper, remove all gasket material from the cylinder block surfaces.

2. CLEAN CYLINDER BLOCK

Using a soft brush and solvent, clean the block.

3. INSPECT CYLINDERS

Visually inspect cylinders for vertical scratches. If deep scratches are present, re bore all six cylinders. (See page EM-50)

4. INSPECT CYLINDER BLOCK WARPAGE

If warpage is greater than the specified value, replace the cylinder block.

5. MEASURE CYLINDER BORE

Using a cylinder micrometer, measure the cylinder bore at positions A. B and C in the thrust and axial directions.

If any of the following measurements are not within the specification, rebore the cylinder. (See page EM-50)

(a) Cylinder diameter is greater than the maximum permissible limit.

On standard sized piston

Maximum diameter: 83.25 mm (3.2776 in.)

On oversized piston (O/S 0.50)

Maximum diameter: 83.75 mm (3.2972 in.)

On oversized piston (O/S 0.75)

Maximum diameter: 84.00 mm (3.3071 in.)

On oversized piston (O/S 1.00)

Maximum diameter: 84.25 mm (3.3169 in.)

(b) If the difference between measurements A, B and C is greater than the taper limit, rebore the cylinder. (See page EM-50)

(c) If the difference between thrust and axial measurements is greater than the out-of-round limit, rebore the cylinder. (See page EM 50)

6. REMOVE CYLINDER RIDGE

If wear is less than 0.2 mm (0.008 in.), use a ridge reamer to machine the piston ring ridge at the top of the cylinder.

DISASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLY

1. CHECK FIT BETWEEN PISTON AND PIN

Try to move the piston back and forth on the piston pic\. If any movement is felt, replace the piston and pin.

2. REMOVE PISTON RINGS

Using a piston ring expander, remove the piston rings. Keep the rings for each cylinder separated.

Piton Ring Position For Toyota

3. DISCONNECT CONNECTING ROD FROM PISTON

(a) Using needle-nose pliers, remove the snap rings from the piston.

(b) Heat the piston in hot water to approx. 60°C (140°F).

<c) Using a plastic-faced hammer and driver, tap the pin lightly to remove the pin from the piston,

NOTE:

• The piston and pin are a matched set.

• Keep the piston, piston pin and rings and connecting rod together for each cylinder.

INSPECTION OF PISTON AND CONNECTING ROD ASSEMBLY

1. CLEAN PISTON

(a) Scrape any carbon from the piston top.

(b) Using a grooved cleaning tool or broken ring, clean the ring grooves.

(c) Using a brush and solvent, clean the piston thoroughly.

CAUTION: Do not use a wire brush.

0 Thrust Direction

(2) Axial Direction

0 Thrust Direction

(2) Axial Direction

2. MEASURE PISTON DIAMETER

(a) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 22 mm (0.87 in.) from the piston head.

Standard diameter: 82.93 - 82.98 mm

(b) Check that the difference between the cylinder diameter and the piston diameter is within specification. (See step 5 on page EM-48)

If not wuthin specification, replace the piston and/or re-bore all six cylinders. (See page EM-52)

MEASURE CLEARANCE BETWEEN PISTON RING GROOVE AND PISTON RING

Using a feeler gauge, measure the clearance between the piston ring and the ring land.

If the clearance is greater than maximum, replace the piston ring and if necessary, the piston

MEASURE RING END GAP

(a) Insert the piston ring into the cylinder bore.

(b) Using a piston, push the piston ring a little beyond the bottom of the ring travel.

{100 mm (3.94 in.) from top surfage of cylinder blockl

(c) Using a feeler gauge, measure the end gap.

Ring end gap:

If not within specification, replace the ring. Do not file the ring end.

CHECK PISTON PIN FIT

At 60°C (140°F), the pin should be able to be pushed into the piston with your thumb.

If the pin can be installed at a lower temperature, replace the piston and pin.

VMVttfMOKO

6. INSPECT CONNECTING RODS

(a) Using a rod aligner, check the connecting rod alignment.

• Check that the rod is not bent. Bend limit:

• Check that the rod is not twisted. Twist limit:

0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If the rod is bent or twisted, replace the connecting rod.

f M174?

Oil Hole

(b) Measure the oil clearance between the rod bushing and piston pin.

• Using an inside dial indicator, measure the inside diameter of the rod bushing.

• Using a micrometer, measure the diameter of the piston pin.

• Check that the difference between the measurements is less than the oil clearance limit.

Standard oil clearance: 0.005 - 0.011 mm

(0.0002 - 0.0004 in.) Maximum oil clearance: 0.015 mm (0.0006 in.) If the clearance is greater than maximum, replace the rod busing.

REPLACEMENT OF ROD BUSHING

1. REMOVE ROD BUSHING

Using SST, remove the rod bushing from the connecting rod.

SST 09222-30010

2. INSTALL NEW ROD BUSHING

Using SST, install the rod bushing to the connecting rod. SST 09222-30010

NOTE: Align the bushing oil hole with the connecting rod oil hole.

Size

Outsid« diameter mm (in.)

0/S 0.50

83.43 - 83.48 (3.2846 - 3.2866)

O'S 0.75

83.68 - 83.73 (3.2945 - 3.2965)

0/S 1.00

83.93 - 83.98 <3.3043 - 3 3063)

3. HONE NEW BUSHING AND CHECK PIN FIT IN CONNECTING ROD

(e) Hone the new bushing and check that the oil clearance is within the standard specification.

Standard oil clearance: 0.005 - 0.011 mm

(b) Check the pin fit at normal room temperature.

Coat the pin with engine oil and push the pin into the rod with thumb pressure.

BORING OF CYLINDERS

1. SELECT OVERSIZED PISTON

0/S pistons with pins are available in the sizes listed. Replace pistons in matched sets. Take the largest bore measured and select the oversized piston for that bore. Bore all cylinders for the oversized piston selected.

2. CALCULATE DIMENSION TO BORE CYLINDERS

(a) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 22 mm (0.87 in.) from the piston head.

(b) Calculate the sizo each cylinder is to be rebored as follows:

P - piston diameter C « piston clearance

0.06 - 0.08 mm <0.0024 - 0.0031 In.) H = allowance for honing

3. BORE AND HONE CYLINDERS TO CALCULATED DIMENSIONS

Honing amount: 0.02 mm (0.0008 In.) maximum

CAUTION: Excess honing will destroy the finished roundness.

Front Mark

Front Mark

Front Mark

Front Mark

(Ml/

Upper Side Rail

• %

Compression . R.ng No. 1& Expander

1

y Lower Side Rail

ASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLY

1. ASSEMBLE PISTON AND CONNECTING ROD

(a) Install a new snap ring on one side of the piston pin hole.

(b) Heat the piston in hot water to approx. 60°C (140°F).

(c) Align the notch on the piston with the mark on the rod and push the piston pin in with your thumb.

(d) Install a new snap ring on the other side of the pin.

2. PLACE RINGS ON PISTON

(a) Using a ring expander, install the top two compression rings with the code marks facing up.

(b) Position the piston rings so that the ring end gaps are in the shaded area as shown.

CAUTION: Do not align the end gaps.

3. INSTALL BEARINGS

4a) Install the bearings in the connecting rods and rod caps.

<b) Lubricate the face of the bearings with engine oil.

INSPECTION AND REPAIR OF CRANKSHAFT

1. MEASURE CRANKSHAFT

(a) Place the crankshaft on V-blocks.

(b) Using a runout gauge, measure the circle runout at the center journal.

Maximum circle runout: 0.06 mm (0.0024 in.)

If the runout is grerater than maximum, replace the crankshaft.

(c) Using a micrometer, check the diameter of the main and crank pin journal.

Measure the journals for out-of-round and taper as shown.

Main journal diameter: 59.988 - 60.012 mm

<2.3617 - 2.3627 in.) Crank pin diameter: 51.976 — 52.000 mm

<2.0463 - 2.0472 in.) Taper and out-of-round limit: 0.02 mm (0.0008 In.)

If journals are worn, regrind or replace the crankshaft.

2. GRIND CRANK NECESSARY

PIN ANO/OR MAIN JOURNAL IF

Grind the crank pins and/or main journals to the undersized finished diameter.

Install a new pin and/or main undersize bearings. Bearing size (U/S 0.25, 0.501 Main journal finished diameter:

U/S 0.25 59.730 - 59.740 mm (2.3516 - 2.3520 in.) U/S 0.50 59.480 - 59.490 mm {2.3417 - 2.3421 in.)

Crank pin finished diameter:

U/S 0.25 51.726 - 51.735 mm (2.0364 - 2.0368 in.) U/S 0.50 51.475 - 51.485 mm (2.0266 - 2.0270 in.)

Taper and out-of-round limit: 0.02 mm (0.0008 in.)

No. 1 ßearing Replacement SST

No. 2 Bearing

INSPECTION AND REPAIR OF OIL PUMP DRIVE SHAFT COMPONENTS

1. INSPECT OIL PUMP DRIVE SHAFT

(a) Using a micrometer, measure the journal diameter.

Standard journal diameter:

Front 40.959 - 40.975 mm (1.6126 - 1.6132 in.) Rear 32.959 - 32.975 mm (1.2976 - 1.2982 in.)

(b) Using a cylinder micrometer, measure the bearing bore.

(c) Subtract the journal diameter measurement from the bearing bore measurement.

Standard oil clearance: 0.025 — 0.066 mm

(0.0010 - 0.0026 in.) Maximum oil clearance: 0.08 mm (0.0031 In.)

If the clearance is greater than maximum, replace the bearing and/or drive shaft.

2. IF NECESSARY, REPLACE DRIVE SHAFT BEARING

(a) Using SST, replace the No. 1 bearing, using the No. 2 bearing as a guide.

SST 09215 00100 (09215-00120, 09215-00150, 09215-00160, 09215-00210, 09215 00220)

No. 2 Bearing Replacement

No. 2 Bearing Replacement

No. 2 Bearing No. 1 Bearing

Front

No. 2 Bearing No. 1 Bearing

Front

NMT6

(b) Using SST, replace the No. 2 bearing, using the No. 1 bearing as a guide.

SST 09215-00100 (09215 00120, 09215-00150, 09215 00160, 09215-00210, 09215 00220)

CAUTION: When inserting the bearings, align each oil hole.

3. INSPECT OIL PUMP ORIVE SHAFT THRUST CLEARANCE

Using a feeler gauge, measure the drive shaft thrust clearance between the thrust plate and collar.

Standard thrust clearance:

Maximum thrust clearance:

0.06 — 0.13 mm (0.0024 - 0.0051 in.) 0.3 mm (0.012 in.)

If clearance is greater than maximum, replace the thrust plate and/or collar.

4. IF NECESSARY, REPLACE THRUST PLATE AND COLLAR

(a) Using SST, remove the thrust plate and collar. SST 09950-20016

(b) Install the thrust plate and collar in the order as shown.

(c) Using a pross, install the thrust plate and collar.

5. IF NECESSARY, REPLACE OIL PUMP GUIDE BUSHING

(a) Drive out the bushing from the outer side of the block.

(b) Drive in the bushing from the inside of the block with a suitable tool.

NOTE: The oil hole should be positioned toward the crankshaft side.

(c) Make sure the front mark of the bushing is positioned toward the front of block.

(MIM* IMVH

REPLACEMENT OF OIL SEALS

NOTE: There are two ways of oil seal replacement

1. IF TIMING BELT CASE IS REMOVED FROM CYLINDER BLOCK (Replacement of front oil seal and pump drive oil seal)

(a) Using a screwdriver, remove the oil seal.

(b) Apply MP grease to the oil seal lip.

(c) Using SST, install the new oil seal. SST 09214 41010 and 09506-35010

2. IF REAR OIL SEAL RETAINER IS REMOVED FROM CYLINDER BLOCK (Replacement of rear oil seal)

(a) Using a screwdriver, remove the oil seal.

(b) Apply MP grease to the oil seal lip.

(c) Using SST, install the new oil seal. SST 09223 41020

3. IF TIMING BELT CASE IS INSTALLED ON CYLINDER BLOCK (Replacement of front oil seal)

(a) Using SST, remove the front oil seal.

SST 09308-10010

(b) Apply MP grease to the oil seal lip.

(c) Using SST, install the new oil seal. SST 09214-41010 and 09506-35010

Cut Position *_b
Tape

IF TIMING BELT CASE IS INSTALLED ON CYLINDER BLOCK (Replacement of pump drive oil seal)

(a) As shown in the figure, use a knife to cut off the oil seal lip.

(b) Using a screwdriver, pry out the oil seal.

NOTE: Be careful not to damage drive shaft. Tape the screwdriver tip.

(c) Check the drive pump shaft where it contacts the oil lip surface for cracks or damage.

(d) Apply MP grease to the oil seal.

(e) Using SST, install the new oil seal. SST 09214-41010

Cut Position
(MOM? tMt»l

5. IF REAR OIL SEAL RETAINER IS INSTALLED ON CYLINDER BLOCK (Replacement of rear oil seal)

(a) As shown in the figure, use a knife to cut off the oil seal lip.

(b) Using a screwdriver, pry out the oil seal.

NOTE: Be careful not to damage the crankshaft. Tape the screwdriver tip.

(c) Check the crankshaft where it contacts the oil lip surface for cracks or damage.

(d) Apply MP grease to the oil seal.

(e) Using SST, install the new oil seal. SST 09223-41020

1M0770

ASSEMBLY OF CYLINDER BLOCK (See page EM-38)

1. INSTALL UPPER MAIN BEARING IN CYLINDER BLOCK

(a) Place the upper main bearing in the block.

(b) Install the upper thrust washers on the center bearing with the oil grooves facing out.

(c) Lubricate the faces of the bearings with engine

2. PLACE CRANKSHAFT IN CYLINDER BLOCK

3. INSTALL MAIN BEARING CAPS

NOTE: Each bearing cap is numbered.

(a) Install thrust washers on No. 4 bearing cap with oil grooves facing out.

(b) Install the bearing caps in numbered order with arrows facing forward. Tighten the bolts to the specified torque in the sequence shown and in two or three passes.

Use Dial Gauge Inspection Crankshaft

(c) Install the dial gauge and measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.

(d) Check that the crankshaft turns.

Step Installation Piston Pin

4. INSTALL PISTON AND CONNECTING ROD ASSEMBLY

(a) Lubricate the cylinder bore and the crankshaft pin with clean engine oil.

(b) Using a ring compressor, push the correctly numbered piston and rod assembly into each cylinder. Make sure the notch and mark are facing forward.

5. INSTALL ROD BEARING CAPS

(a) Match the numbered cap with the numbered rod.

(b) Align the marks punched on the rod and cap and tighten the cap nuts to specified torque alternately in two or three passes.

(c) After tightening the caps, check that the crankshaft rotates smoothly.

6. MEASURE ROD THRUST CLEARANCE

(See step 16 on page EM-43)

7. INSTALL OIL PUMP ASSEMBLY

(b) Install the oil pump and holding bolt. Torque the bolt.

(c) Install the oil pipe with gasket, lock washer and union bolt. Tighten the oil pipe nut and bolt.

8. INSTALL OIL PUMP DRIVE SHAFT

While turning the drive shaft, slowly insert so as not to damage the drive shaft bearing. Torque the bolt.

9. INSTALL REAR OIL SEAL RETAINER

10. INSTALL TIMING BELT CASE WITH WATER PUMP

(a) Position a new gasket on the cylinder block.

(b) Install the timing belt case with eight bolts and two nuts.

Torque:

8 mm bolt and nut 185 kg-cm

11. INSTALL OIL PAN (See page LU-7)

12. INSTALL WATER BY-PASS PIPE

13. INSTALL FUEL HOSE SUPPORT

14. INSTALL FUEL FILTER

15. INSTALL ALTERNATOR

16. INSTALL OIL LEVEL GAUGE

17. INSTALL NEW OIL FILTER

18. INSTALL CYLINDER HEAD ASSEMBLY

(a) Install the cylinder head assembly.

(b) Using SST, install and tighten the cylinder head bolts. SST 09043 38100

(c) Install the air intake chamber stay.

(d) Install the No.2 timing belt cover.

(e) Install the timing belt. (See page EM-14 to 17)

(f) Connect the PCV hose to the cylinder block.

(g) Connect the No.1 water by-pass hose to the water by-pass pipe.

19. REMOVE ENGINE STAND

20. INSTALL REAR END PLATE

21. INSTALL FLYWHEEL OR DRIVE PLATE ON CRANKSHAFT

Install the flywheel or drive plate on crankshaft with six bolts. Torque the bolts.

22. INSTALL CLUTCH DISC AND COVER TO FLYWHEEL (for M/T)

Was this article helpful?

0 0
Simple Car Care Tips and Advice

Simple Car Care Tips and Advice

Put an End to All Your Car Troubles. Does Your Car Break Down Often? Are You Spending More On Fuel Than You Thought You Would? Is Maintaining Your Car Eating Into Your Budget? Make Your Car Last Longer with Some Simple Do It Yourself Tips.

Get My Free Ebook


Responses

  • courtney
    How to piston ring gap alignment?
    9 years ago
  • Mackenzie
    How to change toyota truck differential support bearing 1989?
    9 years ago
  • Vivaldo
    What is a connecting rod thrust clearance?
    4 years ago
  • AMAN
    How to calculate my toyota corolla 79mm bore piston ring gap?
    3 years ago

Post a comment