Engine Mechanical Cylinder Block: Overview Toyota Prius I рестайлинг

Identifying Cylinder Block Components (1 Of 2). Scheme 173

Identifying Cylinder Block Components (2 Of 2). Scheme 174

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1. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY.
2. REMOVE TIMING CHAIN. Refer to REMOVAL.
3. REMOVE CYLINDER HEAD. Refer to REMOVAL.
4. REMOVE ENGINE WIRE.
5. REMOVE WATER BYPASS PIPE. Remove the 2 nuts, bolt and water bypass pipe. (Scheme 175): Removing Water Bypass Pipe Nuts And Bolt
6. REMOVE THERMOSTAT Refer to REMOVAL.
7. REMOVE KNOCK SENSOR Refer to REMOVE KNOCK SENSOR.
8. REMOVE OIL PRESSURE SWITCH Refer to REMOVE OIL PRESSURE SWITCH.
9. REMOVE ENGINE COOLANT DRAIN UNION
10. REMOVE OIL FILTER Refer to REMOVE OIL FILTER.
11. REMOVE OIL FILTER UNION. Using a 12 mm hexagon wrench, remove the oil filter union. (Scheme 176): Removing Oil Filter Union
12. REMOVE OIL PAN NO. 2 Remove the 9 bolts and 2 nuts. Insert the blade of SST between the oil pan No. 1 and oil pan No. 2, and cut off applied sealer and remove the oil pan. (Scheme 177): Removing Oil Pan No. 2 SST 09032-00100 NOTE: Be careful not to the damage the oil pan contact surface of the oil pan No. 1. Be careful not to damage the oil pan No. 2 flange.
13. REMOVE OIL STRAINER. Remove the bolt and 2 nuts, oil strainer and gasket. (Scheme 178): Locating Oil Strainer Nuts And Bolt
14. REMOVE OIL PAN NO. 1 Uniformly loosen and remove the 13 bolts, in several passes, in the sequence shown. (Scheme 179): Removing Oil Pan No. 1 Using screwdriver remove the oil pan No. 1 by prying the portions between the cylinder block and oil pan No. 1. (Scheme 180): Locating Cylinder Block And Oil Pan No. 1 Portions Remove the 2 O-rings from the cylinder block.
15. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.16 - 0.36 mm (0.0063 - 0.0142 in.) Maximum thrust clearance: 0.36 mm (0.0142 in.) (Scheme 181): Measuring Connecting Rod Thrust Clearance If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
16. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. (Scheme 182): Checking Matchmarks On Connecting Rod And Cap Remove the 2 connecting rod cap bolts. NOTE: Keep the lower bearing inserted with the connecting rod cap. (Scheme 183): Removing Connecting Rod Cap With Bolts Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. Clean the crank pin and bearing. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. Lay a strip of Plastigage the crank pin. (Scheme 184): Laying A Plastigage Strip Install the connecting rod cap with the 2 bolts. (See «REASSEMBLY»(ref-182299-S38134379452005080800000) ) Torque: 1ST 15 N.m (150 kgf.cm, 11 ft.lbf) 2ND Turn 90° (Scheme 185): Installing Connecting Rod Cap Bolts NOTE: Do not turn the crankshaft. Remove the 2 bolts, connecting rod cap and lower bearing. (See procedure (b) and (c) above) Measure the Plastigage at its widest point. Standard oil clearance: 0.016 - 0.040 mm (0.0006 - 0.0016 in.) Maximum oil clearance: 0.06 mm (0.0024 in.) (Scheme 186): Measuring Plastigage At Its Widest Point If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft. NOTE: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly. (Scheme 187): Identifying Marks Reference STANDARD BEARING CENTER WALL THICKNESS Mark mm (in.) "1" 1.488 - 1.492 (0.0586 - 0.0587) "2" 1.492 - 1.496 (0.0587 - 0.0589) "3" 1.496 - 1.500 (0.0589 - 0.0591) Completely remove the plastigage.
17. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES NOTE: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order. Using a ridge reamer, remove all the carbon from the top of the cylinder. (Scheme 188): Removing All Carbon From Top Of Cylinder Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
18. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the crankshaft back and forth. Standard thrust clearance: 0.09 - 0.19 mm (0.0035 - 0.0075 in.) Maximum thrust clearance: 0.3 mm (0.012 in.) (Scheme 189): Measuring Thrust Clearance If the thrust clearance is greater than maximum, replace the thrust washer as a set. Thrust washer thickness: 2.430 - 2.480 mm (0.09567 - 0.09764 in.)
19. REMOVE BEARING CAPS AND CHECK OIL CLEARANCE Uniformly loosen and remove the 10 bearing cap bolts in several passes in the sequence shown. (Scheme 190): Identifying Bearing Cap Bolts NOTE: Keep the lower bearing inserted with the bearing cap. (Scheme 191): Removing Bearing Cap Using 2 Removed Bearing Cap Bolts Using the 2 removed bearing cap bolts, remove the bearing cap and lower bearing by wiggling the bearing cap right and left. NOTE: Keep the upper bearings and thrust washers together with the cylinder block. Lift out the crankshaft. Clean each main journal and bearing. Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearing. If necessary, grind or replace the crankshaft. Place the crankshaft on the cylinder block. Lay a strip of plastigage across each journal. (Scheme 192): Applying A Strip Of Plastigage Across Journal NOTE: Do not turn the crankshaft. If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then selecting the bearing with the same number as the total. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly. Install the bearing caps. Refer to INSTALLATION. Torque: 1ST 22 N.m (220 kgf.cm, 16 ft.lbf) 2ND Turn 90° Remove the bearing caps (See procedure (a) and (b) above). Measure the plastigage at its widest point. Standard oil clearance: 0.010 - 0.023 mm (0.0004 - 0.0009 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) (Scheme 193): Measuring Plastigage At Its Widest Point If the oil clearance is greater then maximum, replace the bearings. If necessary, replace the crankshaft. EXAMPLE: Cylinder block "4" (A) + Crankshaft "3" (B) = Total number 7 (Use bearing "3") (Scheme 194): Standard Bearing Number Mark Reference Chart (Scheme 195): Identifying Number Marks (Scheme 196): Journal Diameter And Bearing Thickness Reference Chart Completely remove the Plastigage.
20. REMOVE CRANKSHAFT Lift out the crankshaft. NOTE: Arrange the main bearings and thrust washers in the correct order. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block.
21. CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. (Scheme 197): Checking Piston Pin Fit
22. REMOVE PISTON RINGS NOTE: Arrange the piston rings in the correct order only. (Scheme 198): Removing Compression Rings Using a piston ring expander, remove the 2 compression rings. Remove the oil ring by hand.
23. DISCONNECT CONNECTING ROD FROM PISTON NOTE: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in correct order. Using SST, press out the piston pin from the piston. Remove the piston. SST 09221-25026 (09221-00021, 09221-00030, 09221-00190, 09221-00141, 09221-00150)

Disconnecting Connecting Rod From Piston. Scheme 199

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1. REMOVE GASKET MATERIAL Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. (Scheme 200): Removing Gasket Material
2. CLEAN CYLINDER BLOCK NOTE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at a temperature of 45°C (133°F) or less. Using a soft brush and solvent, thoroughly clean the cylinder block.
3. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) (Scheme 201): Inspecting Top Surface Of Cylinder Block For Flatness If warpage is greater than maximum, replace the cylinder block.
4. INSPECT CYLINDER BORE DIAMETER Visually check the cylinder for vertical scratches. (Scheme 202): Checking Cylinder For Scratches If deep scratches are present, replace the cylinder block.
5. INSPECT CYLINDER BORE DIAMETER Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: 75.000 - 75.013 mm (2.95275 - 2.95326 in.) Maximum diameter: 75.013 mm (2.95326 in.) (Scheme 203): Measuring Cylinder Bore Diameter If the diameter is greater than maximum, replace the cylinder block.
6. REMOVE CYLINDER RIDGE (Scheme 204): Removing Cylinder Ridge If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.
7. INSPECT 12 POINTED HEAD BEARING CAP SUB-ASSEMBLY BOLTS Using vernier calipers, measure the tension portion diameter of the bolt. (Scheme 205): Measuring Tension Portion Diameter Of Bolt Standard diameter: 7.3 - 7.5 mm (0.287 - 0.295 in.) Minimum diameter: 7.3 mm (0.287 in.) If the diameter is less than minimum, replace the bolt.
8. CLEAN PISTON Using a gasket scraper, remove the carbon from the piston top. (Scheme 206): Removing Carbon From Piston Top Using a groove cleaning tool or broken ring, clean the piston ring grooves. (Scheme 207): Cleaning Piston Ring Grooves NOTE: Do not use a wire brush. Using solvent and a brush, thoroughly clean the piston. (Scheme 208): Cleaning Piston Thoroughly Using Solvent And A Brush
9. INSPECT PISTON OIL CLEARANCE Using a micrometer, while placing the piston up side down, take measurement at the position of 27 mm (1.06 in.). Piston diameter: 74.930 - 74.940 mm (2.94999 - 2.95039 in.) Measure the cylinder bore diameter in the thrust directions. (See procedure in step 5 ) (Scheme 209): Measuring Piston Diameter Using Micrometer Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.045 - 0.068 mm (0.00177 - 0.00268 in.) Maximum oil clearance: 0.095 mm (0.0037 in.) If the oil clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder block.
10. INSPECT PISTON RING END GAP Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove. (Scheme 210): Measuring Clearance Between New Piston Ring And Wall Of Ring Groove Ring groove clearance: 0.030 - 0.070 mm (0.0012 - 0.0028 in.) If the clearance is not as specified, replace the piston.
11. INSPECT PISTON RING END GAP Insert the piston ring into the cylinder bore. (Scheme 211): Inserting Piston Ring Into Cylinder Bore Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. Using a feeler gauge, measure the end gap. (Scheme 212): Inspecting Piston Ring End Gap Standard end gap: No. 1: 0.22 - 0.32 mm (0.0087 - 0.0126 in.) No. 2: 0.32 - 0.47 mm (0.0126 - 0.0185 in.) Oil (Side rail): 0.15 - 0.45 mm (0.0059 - 0.0177 in.) Maximum end gap: No. 1: 0.88 mm (0.0346 in.) No. 2: 1.03 mm (0.0406 in.) Oil: 0.92 mm (0.0362 in.) If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block.
12. INSPECT CONNECTING ROD ALIGNMENT Using a rod aligner and feeler gauge, check the connecting rod alignment. (Scheme 213): Inspecting Connecting Rod Alignment (Out Of Alignment) Check for out-of-alignment Maximum out-of alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If out-of alignment is greater than maximum, replace the connecting rod assembly. Check for twist (Scheme 214): Inspecting Connecting Rod Alignment (Twist) Maximum twist: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connecting rod assembly.
13. INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the connecting rod bushing. (Scheme 215): Measuring Inside Diameter Of Connecting Rod Bushing Bushing inside diameter: 18.010-18.019 mm (0.7091-0.7094 in.) Using a micrometer, measure the piston pin diameter. (Scheme 216): Measuring Piston Pin Diameter Piston pin diameter: 17.988-18.007 mm (0.7086-0.7089 in.) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.009-0.015 mm (0.0003-0.0006 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set.
14. INSPECT CONNECTING ROD BOLTS Using a vernier calipers, measure the tension portion diameter of the bolt. (Scheme 217): Measuring Tension Portion Diameter Of Bolt Standard diameter: 6.6-6.7 mm (0.260-0.264 in.) Minimum diameter: 6.4 mm (0.252 in.) If the diameter is less than minimum, replace the bolt.
15. INSPECT CRANKSHAFT FOR CIRCLE RUNOUT Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout (Scheme 218) Maximum circle runout: 0.03 mm (0.0012 in.) (Scheme 218): Measuring Circle Runout If the circle runout is greater than maximum, replace the crankshaft.
16. INSPECT MAIN JOURNALS AND CRANK PINS Using a micrometer, measure the diameter of each main journal and crank pin. (Scheme 219): Measuring Diameter Of Each Main Journal And Crank Pin Main journal diameter: 45.988-46.000 mm (1.81054-1.81102 in.) Crank pin diameter: 39.992-40.000 mm (1.5745-1.5748 in.) If the diameter is not as specified, check the oil clearance. See «DISASSEMBLY»(ref-182299-S00138165982005080800000) If necessary, replace the crankshaft. Check each main journal and crank pin for taper and out-of-round as shown. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of round is greater than maximum, replace the crankshaft.