CYLINDER BLOCK REPLACEMENT


  1. REPLACE CONNECTING ROD SMALL END BUSH


    1. A01DMRPE04

      Using SST and a press, press out the bush.

      SST
      09222-30010
    2. A01DU0XE07
      Text in Illustration
      *1 Oil Hole

      Align the oil holes of a new bush and the connecting rod.

    3. A01DMRPE05

      Using SST and a press, press in the bush.

      SST
      09222-30010
    4. A01DRP8E01

      Using a pin hole grinder, hone the bush to obtain the standard specified clearance between the bush and piston pin.

    5. Check that the piston pin fits at normal room temperature.


      1. Coat the piston pin with engine oil and push it into the connecting rod with your thumb.

  2. REPLACE TIGHT PLUG

    Note

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

    A01DQQIE03
    Text in Illustration
    *a Front Side *b Intake Side
    *c Rear Side *d Exhaust Side

    1. Apply adhesive to new tight plugs.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

    2. Using SST, tap in the 8 tight plugs labeled A and C.

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

    3. Using SST, tap in the tight plug labeled B.

      SST
      09950-60010   ( 09951-00300 )
      09950-70010   ( 09951-07100 )

    4. Using SST, tap in the 3 tight plugs labeled D.

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

  3. REPLACE STRAIGHT PIN

    Note

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


    1. A01DQ7PE03
      Text in Illustration
      *1 Protrusion
      *a Rear Side

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

      Standard Straight Pin
      Item Wide Protrusion
      Pin A 10 mm (0.394 in.) 13 mm (0.512 in.)
      Pin B 6.0 mm (0.236 in.) 5.5 mm (0.217 in.)

  4. REPLACE RING PIN

    Note

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

    A01DO4OE03
    Text in Illustration
    *1 Height *2 Width
    *3 Protrusion - -
    *a Front Side *b Lower Side
    *c Upper Side - -

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

      Standard Ring Pin
      Item Height Width Protrusion
      Pin A 9.0 mm (0.354 in.) 11 mm (0.433 in.) 3.5 to 4.5 mm (0.138 to 0.177 in.)
      Pin B 14 mm (0.511 in.) 15 mm (0.591 in.) 7.5 to 9.5 mm (0.295 to 0.374 in.)
      Pin C 20 mm (0.787 in.) 14 mm (0.511 in.) 7.0 to 9.0 mm (0.276 to 0.354 in.)