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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 24 (Engine Mechanical System (A25A-FXS) - Service Information (3 Of 3)) >> Cylinder Block >> Disassembly [10/2022 - 11/2023] >> Procedure

Disassembly [10/2022 - 11/2023]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE NO. 1 VENTILATION CASE 
    WARNING:
    • When the No. 1 ventilation case is fastened using only bolt A:

      Do not disassemble except if the No. 1 ventilation case to be damaged.

    • When the No. 1 ventilation case is fastened using bolt B:

      Do not remove and install the No. 1 ventilation case.

    GTY1090642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Bolt A *b Bolt B
    1. Remove the 4 bolts and No. 1 ventilation case from the cylinder block sub-assembly.
      GTY756768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 oil separator gaskets from the No. 1 ventilation case.
      GTY771483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT CONNECTING ROD THRUST CLEARANCE 
    1. Using a dial indicator, measure the thrust clearance while moving the connecting rod sub-assembly back and forth.
      GTY757050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Thrust Clearance

      0.16 to 0.51 mm (0.00630 to 0.0201 in.)

      Maximum Thrust Clearance

      0.512 mm (0.0202 in.)

      HINT: 

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

  3. INSPECT CONNECTING ROD OIL CLEARANCE 

    HINT: 

    There are two types of connecting rod sub-assemblies; cracking connecting rods and other than cracking connecting rods.

    GTY1104336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *A except Cracking Connecting Rod *B Cracking Connecting Rod
    *a w/ Pin *b w/o Pin
    1. Note the alignment marks on the connecting rod and connecting rod cap so that they can be reinstalled to their original locations.
      GTY743046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark
    2. Using an E12 "TORX" socket wrench, remove the 2 connecting rod bolts and connecting rod cap.
      GTY772169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Keep the connecting rod bearing and connecting rod cap together.

    3. Clean the crank pin and connecting rod bearing.
    4. Check the crank pin and connecting rod bearing for pitting and scratches.

      HINT: 

      If the crank pin or connecting rod bearing is damaged, replace the connecting rod bearings. If necessary, replace the crankshaft.

    5. Lay a strip of Plastigage on the crank pin.
      GTY746261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
    6. except Cracking Connecting Rod:
      1. 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.
        GTY745201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Front Mark
      2. Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.
      3. Using an E12 "TORX" socket wrench, install and uniformly tighten the 2 connecting rod bolts.
        GTY757048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      4. Using an E12 "TORX" socket wrench, alternately tighten the 2 connecting rod bolts.

        Torque: 38 N.m (387 kgf/cm, 28 ft.lbf) 

      5. Mark the front of each connecting rod bolt with paint.
        GTY757623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Paint Mark
        *b 90°
        Front of Engine
      6. Tighten the connecting rod bolts 90° as shown in the illustration.
        NOTE:

        Do not turn the crankshaft during the measurement.

      7. Check that the paint marks are now at a 90° angle to the front.
    7. Cracking Connecting Rod:
      1. 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.
        GTY745435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Front Mark
      2. Apply a light coat of engine oil to the threads and under the heads of the 2 connecting rod bolts.
      3. Using an E12 "TORX" socket wrench, install and uniformly tighten the 2 connecting rod bolts.
        GTY772169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

        NOTE:

        Do not use electric or air powered tools.

      4. Using an E12 "TORX" socket wrench, alternately tighten the 2 connecting rod bolts.

        Torque: 38 N.m (387 kgf/cm, 28 ft.lbf) 

      5. Mark the front of each connecting rod bolt with paint.
        GTY757623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Paint Mark
        *b 90°
        Front of Engine
      6. Tighten the connecting rod bolts 90° as shown in the illustration.
        NOTE:

        Do not turn the crankshaft during the measurement.

      7. Check that the paint marks are now at a 90° angle to the front.
    8. Remove the 2 connecting rod bolts and connecting rod cap.

      HINT: 

      Keep the connecting rod bearing and connecting rod cap together.

    9. Measure the Plastigage at its widest point.
      GTY756529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
      *b 1, 2 or 3 Mark

      Standard Oil Clearance

      0.027 to 0.059 mm (0.00106 to 0.00232 in.)

      Maximum Oil Clearance

      0.059 mm (0.00232 in.)

      HINT: 

      • If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, replace the crankshaft.
      • If replacing a connecting rod bearing, select a new one with the same number as marked on the connecting rod cap. There are 3 sizes of standard connecting rod bearings, marked "1", "2" or "3" accordingly.

      Standard Connecting Rod Big End Inside Diameter

      Mark Specified Condition
      1 51.000 to 51.008 mm (2.00787 to 2.00818 in.)
      2 51.009 to 51.016 mm (2.00822 to 2.00850 in.)
      3 51.017 to 51.024 mm (2.00854 to 2.00881 in.)

      Standard Connecting Rod Bearing Center Wall Thickness

      Mark Specified Condition
      1 1.487 to 1.491 mm (0.0585 to 0.0587 in.)
      2 1.492 to 1.495 mm (0.0587 to 0.0589 in.)
      3 1.496 to 1.499 mm (0.0589 to 0.0590 in.)

      Standard Crank Pin Diameter

      47.992 to 48.000 mm (1.88945 to 1.88976 in.)

      NOTE:

      Remove the Plastigage completely after the measurement.

    10. Perform the inspection above for each cylinder.
  4. REMOVE PISTON WITH CONNECTING ROD 
    1. Using a ridge reamer, remove all the carbon from the top of each cylinder.
      GTY760492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Ridge Reamer
    2. Remove the 8 connecting rod bolts, 4 connecting rod caps and 4 connecting rod bearings.
    3. Push the 4 pistons, 4 connecting rods and 4 connecting rod bearings out through the top of the cylinder block sub-assembly.

      HINT: 

      • Keep the connecting rod bearings, connecting rods and connecting rod caps together.
      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.
  5. REMOVE CONNECTING ROD BEARING 
    1. Remove the 8 connecting rod bearings from the 4 connecting rods and 4 connecting rod caps.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  6. INSPECT CRANKSHAFT THRUST CLEARANCE 
    1. Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.
      GTY757108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Thrust Clearance

      0.09 to 0.19 mm (0.00354 to 0.00748 in.)

      Maximum Thrust Clearance

      0.25 mm (0.00984 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

      2.43 to 2.48 mm (0.0957 to 0.0976 in.)

  7. REMOVE CRANKSHAFT 
    1. Uniformly loosen and remove the 10 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.
      GTY763911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 crankshaft bearing caps from the cylinder block sub-assembly.

      HINT: 

      • Keep the No. 2 crankshaft bearings and crankshaft bearing caps together.
      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.
    3. Remove the crankshaft from the cylinder block sub-assembly.

      HINT: 

      Keep the crankshaft bearings and crankshaft thrust washers together with the cylinder block sub-assembly.

    4. Check each crankshaft journal and crankshaft bearing for pitting and scratches.

      If the journal or crankshaft bearing is damaged, replace the crankshaft bearings. If necessary, replace the crankshaft.

  8. REMOVE CRANKSHAFT THRUST WASHER 
    1. Remove the 2 crankshaft thrust washers from the No. 3 journal position of the cylinder block sub-assembly.
      GTY772181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE CRANKSHAFT BEARING 
    1. Remove the 5 crankshaft bearings and 5 No. 2 crankshaft bearings from the cylinder block sub-assembly and 5 crankshaft bearing caps.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  10. REMOVE PISTON RING SET 
    1. Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring from the piston.
      GTY753737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Piston Ring Expander
    2. Remove the oil ring expander, upper side rail and lower side rail from the piston by hand.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  11. REMOVE PISTON PIN HOLE SNAP RING 
    1. Using a screwdriver, pry out the 2 piston pin hole snap rings from the piston.
      GTY766034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front Mark Cutout Portion
      *b Protective Tape

      HINT: 

      Tape the screwdriver tip before use.

  12. REMOVE PISTON 
    1. Gradually heat each piston to between 80 and 90°C (176 and 194°F).
      GTY757106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      WARNING:

      Be sure to wear protective gloves.

    2. Using a brass bar and a hammer, lightly tap out the piston pin and remove the connecting rod.
      GTY757100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      • 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.
  13. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies from the cylinder block sub-assembly.
      GTY757101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE NO. 2 OIL NOZZLE SUB-ASSEMBLY 
    1. Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 2 oil nozzle sub-assemblies from the cylinder block sub-assembly.
      GTY757102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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