CYLINDER BLOCK REPLACEMENT

PROCEDURE


  1. REPLACE CYLINDER BLOCK TIGHT PLUG

    Note

    If coolant leaks from a tight plug or a plug is corroded, replace it.


    1. Remove the tight plugs.

    2. Apply adhesive to new tight plugs.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Do not start the engine for 1 hour after installation.

    3. Position A:

      Using a 14 mm steel bar and hammer, tap in the tight plug as shown in the illustration.

    4. Other positions:

      Using SST and a hammer, tap in the tight plugs as shown in the illustration.

      Position B

      SST
      09950-60010   ( 09951-00180 )
      09950-70010   ( 09951-07100 )

      Position C

      SST
      09950-60010   ( 09951-00190 )
      09950-70010   ( 09951-07100 )

      Position D

      SST
      09950-60010   ( 09951-00200 )
      09950-70010   ( 09951-07100 )

      Position E and H

      SST
      09950-60010   ( 09951-00350 )
      09950-70010   ( 09951-07100 )

      Position F

      SST
      09950-60010   ( 09951-00400, 09951-00450 )
      09950-70010   ( 09951-07100 )

      Position G

      SST
      09950-60010   ( 09951-00450 )
      09950-70010   ( 09951-07100 )
      A01LG1SC04
      *a Right Side *b Left Side
      *c Front Side *d Rear Side
      *e Stops - -

  2. REPLACE STRAIGHT PIN

    Note

    It is not necessary to remove a straight pin unless it is being replaced.


    1. Remove the straight pins.

    2. Using a plastic-faced hammer, tap in new straight pins to the cylinder block sub-assembly.

      Standard Protrusion Height
      Item Specified Condition
      Pin A 7.5 mm (0.295 in.) or less
      Pin B 6 mm (0.234 in.) or less
      Pin C 12 mm (0.472 in.) or less
      A01LA69C05
      *a Front Side *b Rear Side
      *c Pin A *d Pin B
      *e Pin C *f 18 mm (0.709 in.)
      *g 8 mm (0.3.15 in.) *h 11 mm (0.433 in.)
      *i 6 mm (0.236 in.) *j 22 mm (0.866 in.)
      *k 10 mm (0.394 in.) *l Protrusion height

  3. REPLACE RING PIN

    Note

    It is not necessary to remove a ring pin unless it is being replaced.


    1. Remove the ring pins.

    2. Using a plastic-faced hammer, tap in new ring pins to the cylinder block sub-assembly.

      Standard Protrusion
      6 mm (0.236 in.) or less
      A01L96BC06
      *a Cylinder Head Side *b 10.5 mm (0.413 in.)
      *c 15 mm (0.590 in.) *d 6 mm (0.236 in.) or less

  4. REPLACE CYLINDER BLOCK WATER DRAIN COCK PLUG

    Note

    If coolant leaks from a cylinder block water drain plug or a cylinder block water drain plug is corroded, replace the cylinder block water drain plug.


    1. Remove the cylinder block water drain plug from the cylinder block.

    2. Clean the cylinder block side hole and new cylinder block water drain plug with non-residue solvent.

    3. A01LB1PC01
      *a Front
      *b 5.0 mm (0.197 in.)
      *c 2.0 mm (0.787 in.)
      *d Adhesive

      Apply adhesive onto the shaded area of a cylinder block water drain plug as shown in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Install the cylinder block water drain plug within 3 minutes after applying adhesive.

    4. Set the cylinder block water drain plug and tap it until the edge of the cylinder block water drain plug fits against the chamfered part of the cylinder block as shown in the illustration.