Disassembly

2AZ-FE ENGINE MECHANICAL: CYLINDER BLOCK: DISASSEMBLY

1. INSPECT CONNECTING ROD THRUST CLEARANCE Testing and Inspection

2. INSPECT CONNECTING ROD OIL CLEARANCE Testing and Inspection

3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD





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

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

(b) Using a 12 mm socket wrench, uniformly loosen the 2 bolts.





(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 in the connecting rod cap.

(d) 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.

4. REMOVE CONNECTING ROD BEARING

(a) Remove the connecting rod bearings.

HINT
Arrange the removed parts in the correct order.

5. REMOVE PISTON RING SET

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





(b) Remove the oil ring rail and oil ring expander by hand

HINT
Arrange the removed parts in the correct order.

6. REMOVE PISTON PIN HOLE SNAP RING

(a) Using a screwdriver, pry out the 2 snap rings.





7. REMOVE PISTON

(a) Gradually heat the piston to between 80 and 90°C (176 and 194°F).





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





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

8. INSPECT CRANKSHAFT THRUST CLEARANCE Testing and Inspection

9. REMOVE CRANKSHAFT

(a) Uniformly loosen and remove the 10 main bearing cap bolts in the sequence shown in the illustration.





(b) Use 2 removed main bearing cap bolts to remove the 5 main bearing caps and 5 lower bearings.





NOTICE:
Insert the bolts into one of the caps. Ease the cap out by gently pulling up and applying force toward the front and back side of the cylinder block, as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block.

HINT
* Keep the lower bearing and main bearing cap.
* Arrange the main bearing caps in the correct order.

(c) Lift out the crankshaft.

10. REMOVE UPPER CRANKSHAFT THRUST WASHER

(a) Remove the upper thrust washers from the cylinder block.





11. REMOVE CRANKSHAFT BEARING

(a) Remove the 5 crankshaft bearings from the cylinder block.





HINT
Arrange the removed parts in the correct order.

12. REMOVE NO. 2 CRANKSHAFT BEARING

(a) Remove the 5 No. 2 crankshaft bearings from the 5 main bearing caps.





HINT
Arrange the removed parts in the correct order.

13. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, remove the bolts and oil nozzles.





14. REMOVE STUD BOLT

15. REMOVE RING PIN

16. REMOVE STRAIGHT PIN