CYLINDER BLOCK DISASSEMBLY

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during engine unit removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure		Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Disconnect cable from negative battery terminal		Memorize steering angle neutral point	LKA/LDA System	Click here
			Intelligent clearance sonar system*2
			Pre-crash safety system
			Lighting system (EXT) Cornering lights
			Adaptive high beam system
			Parking Assist Monitor System (w/ Parallel Parking Assist Function)	Click here
			Parking Assist Monitor System (w/o Parallel Parking Assist Function)	Click here
			Panoramic view monitor system	Click here
		Initialize back door lock	Power door lock control system	Click here
		Reset back door close position	Power back door system	Click here
Replacement of ECM		Perform Vehicle Identification Number (VIN) or frame number registration	MIL illuminates / - DTC P063051 is stored	for 2GR-FKS (w/ Canister Pump Module): Click here for 2GR-FKS (w/o Canister Pump Module) Click here
		ECU Communication ID Registration (Immobiliser system)	Engine start function	See Service Bulletin for the registration method.
		Perform code registration (Immobiliser system)	Wireless door lock control system Entry and start system Engine start function Steering lock system Telematics system	See Service Bulletin for the registration method.
Replacement of ECM (If possible, read the transaxle compensation code from the previous ECM)	Possible to read transaxle compensation code	Perform the following procedures in the order shown: Transfer Transaxle Compensation Code Perform Road Test to Allow ECM to Learn	Large shift shock Deterioration of fuel efficiency	Click here for Initialization (U881E) Click here for Registration (U881E) Click here for Initialization (U881F) Click here for Registration (U881F)
	Impossible to read transaxle compensation code	Perform the following procedures in the order shown: Reset Transaxle Compensation Code Perform Road Test to Allow ECM to Learn	Large shift shock Deterioration of fuel efficiency
w/ Canister Pump Module Replacement of cylinder head sub-assembly Replacement of camshaft (for intake or exhaust camshaft) Replacement of camshaft timing gear assembly Replacement of camshaft timing exhaust gear assembly Replacement of piston or piston ring Replacement of fuel injector assembly (for port injection) Replacement of fuel injector assembly (for direct injection) Replacement of fuel pump assembly (for high pressure side) Replacement of engine coolant temperature sensor Replacement of spark plug Replacement of ignition coil assembly Air leaks from intake system Gas leak from exhaust system is repaired Replacement of knock control sensor Replacement of Heated oxygen sensor		Inspection After Repair	Poor idle, etc. Engine start function, etc.	Click here
w/o Canister Pump Module Replacement of cylinder head sub-assembly Replacement of camshaft (for intake or exhaust camshaft) Replacement of camshaft timing gear assembly Replacement of camshaft timing exhaust gear assembly Replacement of piston or piston ring Replacement of fuel injector assembly (for port injection) Replacement of fuel injector assembly (for direct injection) Replacement of fuel pump assembly (for high pressure side) Replacement of engine coolant temperature sensor Replacement of spark plug Replacement of ignition coil assembly Air leaks from intake system Gas leak from exhaust system is repaired Replacement of knock control sensor		Inspection After Repair	Poor idle, etc. Engine start function, etc.	Click here
Replacement of automatic transaxle assembly		Perform the following procedures in the order shown: Reset Memory Input Transaxle Compensation Code into ECM Perform Road Test to Allow ECM to Learn	Large shift shock Deterioration of fuel efficiency	for U881E Initialization: Click here for U881E Registration: Click here for U881F Initialization: Click here for U881F Registration: Click here
Front wheel alignment adjustment		Clear zero point calibration data and store system information. Perform yaw rate and acceleration sensor zero point calibration and store system information.	VSC disabled or malfunctions DTCs are stored Slip indicator light illuminates ABS warning light illuminates Theft deterrent system (tilt sensor)*1	Click here
Suspension, tires, etc. (The vehicle height changes because of suspension or tire replacement)		Ultrasonic sensor detection angle Ultrasonic sensor detection angle registration	Intelligent clearance sonar system LEXUS parking assist-sensor system (w/ Intelligent Clearance Sonar System)	Click here
		Rear television camera assembly optical axis (Back camera position setting)	Parking assist monitor system (w/ Parallel Parking Assist Function)	for Initialization: Click here for Calibration: Click here
			Parking assist monitor system (w/o Parallel Parking Assist Function)	for Initialization: Click here for Calibration: Click here
		Parking assist ECU initialization Adjust steering angle	Panoramic view monitor system	for Initialization: Click here for Calibration: Click here
		Initialize headlight ECU sub-assembly LH	Adaptive high beam system Automatic headlight beam level control system	Click here

*1: w/ TFT Meter Type
*2: When performing learning using the GTS.
Click here Click here

PROCEDURE

REMOVE CYLINDER BLOCK WATER JACKET SPACER
1. Remove the cylinder block water jacket spacer and cylinder block water jacket spacer LH from the cylinder block sub-assembly.
REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD
1. Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned.
  
  Tech Tips
  
  The matchmarks on the connecting rod sub-assembly and connecting rod cap are guides for correct reassembly.
2. Front of Engine
  
  Remove the 2 connecting rod cap bolts.
3. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower connecting rod bearing by wiggling the connecting rod cap right and left.
  
  Tech Tips
  
  Keep the lower connecting rod bearing installed to the connecting rod cap.
4. *a Ridge Reamer
  
  Using a ridge reamer, remove all of the carbon from the top of the cylinder.
5. Push the piston, connecting rod sub-assembly and upper connecting rod bearing through the top of the cylinder block sub-assembly.
  Tech Tips
  - Keep the connecting rod bearing, connecting rod sub-assembly and connecting rod cap together.
  - Arrange the removed parts in such a way that they can be reinstalled to their original locations.
REMOVE CONNECTING ROD BEARING
1. Remove the connecting rod bearings from the connecting rod sub-assembly and connecting rod cap.
  
  Tech Tips
  
  Arrange the removed parts in such a way that they can be reinstalled to their original locations.
REMOVE PISTON RING SET
1. *a Piston Ring Expander
  
  Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring.
2. Remove the oil ring expander and 2 side rails by hand.
  
  Tech Tips
  
  Arrange the removed parts in such a way that they can be reinstalled to their original locations.
REMOVE PISTON
1. Check the fitting condition between the piston and piston pin.
  1. Try to move the piston back and forth on the piston pin.
    
    Tech Tips
    
    If abnormal movement is felt, replace the piston and piston pin as a set.
2. Remove the connecting rod sub-assembly from the piston.
  1. Using a screwdriver, pry out the piston pin hole snap ring (front side).
    
    Note
    
    Do not remove the piston pin hole snap ring (rear side) unless it has to be replaced.
    
    Be careful not to damage the piston when removing the piston pin hole snap ring (rear side).
  2. Gradually heat the piston to approximately 80°C (176°F).
    
    CAUTION:
    
    Be sure to wear protective gloves.
  3. Using a brass bar and a hammer, lightly tap out the piston pin and remove the connecting rod sub-assembly.
    
    Tech Tips
    
    The piston and piston pin are a matched set.
    
    Arrange the removed parts in such a way that they can be reinstalled to their original locations.
3. Using a gasket scraper, remove any carbon from the piston top.
  
  Note
  
  Be careful not to scratch the piston.
4. Using a groove cleaning tool or a broken ring, clean the piston ring grooves.
5. Using solvent and a brush, thoroughly clean the piston.
  
  Note
  
  Do not use a wire brush.

REMOVE CRANKSHAFT

Uniformly loosen and remove the 8 crankshaft bearing cap set bolts and 8 seal washers in several steps in the order shown in the illustration.
Uniformly loosen the 16 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

*1	Cylinder Block Sub-assembly
*2	Crankshaft Bearing Cap
*a	Protective Tape
*b	Contact Surface

Using a screwdriver with its tip wrapped with protective tape, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and lower crankshaft bearings.

Note

Push up the crankshaft bearing cap slowly and evenly, alternating between the right and left side so that the crankshaft bearing cap can be removed.
Be careful not to damage the contact surfaces of the cylinder block sub-assembly and the crankshaft bearing cap.

Remove the crankshaft.

REMOVE CRANKSHAFT BEARING
1. Remove the upper crankshaft bearings and lower crankshaft bearings.
  
  Tech Tips
  
  Arrange the removed parts in such a way that they can be reinstalled to their original locations.
REMOVE CRANKSHAFT THRUST WASHER SET
1. Remove the crankshaft thrust washer set from the cylinder block sub-assembly.
REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Using a 5 mm hexagon socket wrench, remove the 3 bolts and 3 No. 1 oil nozzle sub-assemblies.
2. Check the 3 No. 1 oil nozzle sub-assemblies for damage or clogging.
  
  Tech Tips
  
  If there is damage or clogs, replace the No. 1 oil nozzle sub-assembly.