Cylinder Block Disassembly

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

Standard thrust clearance:

0.15 to 0.35 mm (0.00591 to 0.0138 in.)

Maximum thrust clearance:

0.40 mm (0.0157 in.)

Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.

HINT:

The matchmarks on the connecting rods and caps are for ensuring correct reassembly.

Remove the 2 connecting rod cap bolts.

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 installed to the connecting rod cap.

Clean the crank pin and bearing.

Check the crank pin and bearing for pitting and scratches.

Lay a strip of Plastigage on the crank pin.

Check that the front mark of the connecting rod cap is facing forward.

Install the connecting rod cap (HILUX_TGN26 RM00000125B040X_02_0062.html).

NOTICE:

Do not turn the crankshaft.

Remove the 2 bolts and connecting rod cap (refer to the steps above).

Measure the Plastigage at its widest point.

Standard oil clearance:

0.039 to 0.066 mm (0.00154 to 0.00260 in.)

Maximum oil clearance:

0.066 mm (0.00260 in.)

Standard crankshaft pin diameter:

52.989 to 53.002 mm (2.086 to 2.087 in.)

Standard Bearing Center Wall Thickness:

Item	Specified Condition
Mark 4	1.484 to 1.487 mm (0.05843 to 0.05854 in.)
Mark 5	1.488 to 1.490 mm (0.05858 to 0.05866 in.)
Mark 6	1.491 to 1.493 mm (0.05870 to 0.05878 in.)

Completely remove the Plastigage.

Perform the inspection above for each crank pin.

Using a ridge reamer, remove all the carbon from the top of the cylinder.

Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

HINT:

1. Keep the bearing, connecting rod and cap together.
   
2. Arrange the piston and connecting rod assemblies in the correct order.
   

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

HINT:

Arrange the removed parts in the correct order.

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

Standard thrust clearance:

0.02 to 0.22 mm (0.000787 to 0.00866 in.)

Maximum thrust clearance:

0.30 mm (0.0118 in.)

Thrust washer thickness:

2.440 to 2.490 mm (0.0961 to 0.0980 in.)

Uniformly loosen the 10 bearing cap bolts in several steps in the sequence shown in the illustration.

Remove the 10 bearing cap bolts, 5 bearing caps, 5 lower bearings and 2 lower thrust washers.

HINT:

1. Keep the lower bearings and crankshaft bearing caps together.
   
2. Arrange the thrust washers in the correct order.
   

Lift out the crankshaft to remove it.

Remove the upper thrust washers from the cylinder block.

HINT:

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

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

HINT:

Arrange the removed parts in the correct order.

Using a piston ring expander, remove the 2 compression rings.

Using a piston ring expander, remove the oil ring rail.

Remove the oil ring expander by hand.

HINT:

Arrange the piston rings in the correct order.

Check the fitting condition between the piston and piston pin.

1. 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.
   

Disconnect the connecting rod from the piston.

1. Using a screwdriver, pry off the snap rings from the piston.
   

   Text in Illustration

   *1

   Snap Ring

2. Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).
   





3. Using a brass bar and plastic-faced hammer, lightly tap out the piston pin and remove the connecting rod.
   

   HINT:

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

Using a gasket scraper, remove the carbon from the piston top.

Using a groove cleaning tool or broken ring, clean the piston ring grooves.

Using solvent and a brush, thoroughly clean the piston.

NOTICE:

Do not use a wire brush.

Using a 5 mm hexagon wrench, remove the oil nozzles.

Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.

Standard thrust clearance:

0.07 to 0.13 mm (0.00276 to 0.00512 in.)

Maximum thrust clearance:

0.20 mm (0.00787 in.)

Remove the bolt.

Remove the balance shaft from the cylinder block.

NOTICE:

When removing the balance shaft, be sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block.

Mount the head portion of the balance shaft in a vise.

NOTICE:

Do not damage the balance shaft.

Remove the bolt.

Remove the No. 1 balance shaft driven gear, sliding key, balance shaft thrust washer and balance shaft thrust spacer.

Remove the 2 bolts.

Remove the balance shaft from the cylinder block.

NOTICE:

When removing the balance shaft, be sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block.

Mount the head portion of the balance shaft in a vise.

NOTICE:

Do not damage the balance shaft.

Remove the bolt.

Remove the No. 2 balance shaft driven gear and No. 2 balance shaft thrust washer.

Remove the water drain cock sub-assembly from the cylinder block.

Remove the water drain cock plug from the water drain cock sub-assembly.