CYLINDER BLOCK REPLACEMENT

PROCEDURE


  1. REPLACE CONNECTING ROD SMALL END BUSH


    1. B003QL2N15

      Using SST and a press, press out the connecting rod small end bush.

      SST
      09222-30010
    2. B003N5RC03
      *a Oil Hole

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

    3. B003QL2N15

      Using SST and a press, press in the connecting rod small end bush.

      SST
      09222-30010
    4. B003QNM

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

      Click here

    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 a tight plug or a plug is corroded, replace it.

    B003PZ1C07
    *a Front Side *b Intake Side
    *c Rear Side *d Exhaust Side
    *e 1.0 mm (0.0394 in.) - -

    1. Apply adhesive to new tight plugs.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Using SST, tap in the tight plug labeled A.

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

    3. Using SST, tap in the 8 tight plugs labeled B and D.

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

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

      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. B003RPGC01
      *a Height
      *b Width
      *c Protrusion Height
      *d Rear Side

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

      Standard Straight Pin
      Item Height Width Protrusion
      Pin A 22 mm (0.866 in.) 10 mm (0.394 in.) 13 mm (0.512 in.)
      Pin B 14 mm (0.551 in.) 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.

    B003J3GC06
    *a Front Side *b Lower Side
    *c Upper Side *d Height
    *e Width *f Protrusion Height

    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 20 mm (0.787 in.) 14 mm (0.511 in.) 7.0 to 9.0 mm (0.276 to 0.354 in.)
      Pin C 14 mm (0.511 in.) 15 mm (0.591 in.) 7.5 to 9.5 mm (0.295 to 0.374 in.)