Disassembly

2GR-FSE ENGINE MECHANICAL: CYLINDER BLOCK: DISASSEMBLY

1. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD

(a) Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned.

HINT
The matchmarks on the connecting rod sub-assembly and connecting rod cap are guides for the correct reassembly.

(b) Remove the 2 connecting rod cap bolts.

Text in Illustration

(c) 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.

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

Text in Illustration

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

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

2. REMOVE CONNECTING ROD BEARING

HINT
Arrange the removed parts in the correct order.

3. REMOVE CRANKSHAFT

(a) Uniformly loosen and remove the 8 crankshaft bearing cap bolts and the 8 seal washers in several steps and in the sequence shown in the illustration.

(b) Uniformly loosen the 16 crankshaft bearing cap bolts, in several steps and in the sequence shown in the illustration.

(c) Using a screwdriver, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and lower crankshaft bearings.

Text in Illustration

NOTICE:
* Push up on the cap slowly and evenly, alternating from the right and left side so that the bearing cap can be removed.
* Be careful not to damage the joint surfaces of the cylinder block and the crankshaft bearing cap.

(d) Remove the crankshaft.

4. REMOVE CRANKSHAFT BEARING

(a) Remove the upper crankshaft bearings and lower crankshaft bearings.

HINT
Arrange the removed parts in the correct order.

5. REMOVE CRANKSHAFT THRUST WASHER SET

(a) Remove the upper crankshaft thrust washers from the cylinder block sub-assembly.

6. REMOVE PISTON RING SET

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

Text in Illustration

(b) Remove the oil ring expander and 2 side rails by hand.

HINT
Arrange the removed parts in the correct order.

7. REMOVE PISTON SUB-ASSEMBLY WITH PIN

(a) Disconnect the connecting rod from the piston.

(1) Using a screwdriver, pry off the piston pin hole snap rings from the piston.

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

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

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

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

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

NOTICE:
Do not use a wire brush.

8. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, remove the 3 bolts and No. 1 oil nozzle sub-assemblies.

(b) Check the 3 oil nozzles for damage or clogging.

If necessary, replace the No. 1 oil nozzle sub-assembly.

9. REMOVE CONNECTING ROD SMALL END BUSH

(a) Using SST and press, press out the bush.

SST : 09222-30010

10. CLEAN CYLINDER BLOCK