Toyota Yaris: Cylinder Block / Disassembly

Piston or piston ring

Inspection after repair

(a) Remove the 3 bolts, 2 nuts and No. 1 ventilation case from the cylinder block sub-assembly.

(b) Remove the 3 oil separator gaskets from the No. 1 ventilation case.

(a) Remove the No. 1 cylinder block insulator from the cylinder block sub-aseembly.

(a) Using a dial indicator, measure the thrust clearance while moving the connecting rod sub-assembly back and forth.

Standard Thrust Clearance:

0.15 to 0.50 mm (0.00591 to 0.01969 in.)

Maximum Thrust Clearance:

0.50 mm (0.01969 in.)

HINT:

If the thrust clearance is more than the maximum, replace the connecting rod. If necessary, replace the crankshaft.

(a) Note the alignment marks on the connecting rod and connecting rod cap so that they can be reinstalled to their original locations.

(b) Using an SST wrench, remove the 2 connecting rod bolts and connecting rod cap.

SST: 09205-16011

HINT:

Keep the connecting rod bearing and connecting rod cap together.

(e) Lay a strip of Plastigage on the crank pin.

(f) Check that the front mark of the connecting rod cap is facing the correct direction, and install the connecting rod cap to the connecting rod.

(g) Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.

*a

Paint Mark

*b

90°

Front of Engine

(l) Measure the Plastigage at its widest point.

Standard Oil Clearance:

0.032 to 0.065 mm (0.00126 to 0.00256 in.)

Maximum Oil Clearance:

0.065 mm (0.00256 in.)

Standard Connecting Rod Big End Inside Diameter:

Standard Connecting Rod Bearing Center Wall Thickness:

Standard Crank Pin Diameter:

47.992 to 48.000 mm (1.88945 to 1.88976 in.)

NOTICE:

Remove the Plastigage completely after the measurement.

(a) Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.

Standard Thrust Clearance:

0.02 to 0.22 mm (0.000787 to 0.00866 in.)

Maximum Thrust Clearance:

0.22 mm (0.00866 in.)

HINT:

If the thrust clearance is more than the maximum, replace the crankshaft thrust washers as a set. If necessary, replace the crankshaft.

Standard Thrust Washer Thickness:

2.415 to 2.470 mm (0.0951 to 0.0972 in.)

(a) Uniformly loosen and remove the 8 crankshaft bearing cap set bolts and 10 bolts.

(b) Remove the crankshaft bearing cap assembly from the cylinder block sub-assembly with a screwdriver with its tip wrapped with protective tape..

(a) Remove the 2 crankshaft thrust washers from the No. 3 journal position of the cylinder block sub-assembly.

(a) Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring from the piston.

(a) Using a screwdriver, pry out the 2 piston pin hole snap rings from the piston.

HINT:

Tape the screwdriver tip before use.

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

CAUTION:

Be sure to wear protective gloves.

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

(a) Using a 5 mm hexagon wrench, remove the 3 bolts and 3 No. 1 oil nozzle sub-assemblies from the cylinder block sub-assembly.

(a) Using a 5 mm hexagon wrench, remove the 3 bolts and 3 No. 2 oil nozzle sub-assemblies from the cylinder block sub-assembly.

(a) Using a 5 mm hexagon wrench, remove the 3 bolts and 3 No. 3 oil nozzle sub-assemblies from the cylinder block sub-assembly.