Toyota Corolla 2004 Repair Manual - CYLINDER BLOCK ASSY
OVERHAUL
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–ENGINE MECHANICAL CYLINDER BLOCK ASSY (April, 2003)
140Q9–05
1. REMOVE CYLINDER BLOCK WATER DRAIN COCK
SUB–ASSY
(a) Remove the cylinder block water drain cock from the cyl-
inder block.
2. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
Standard thrust clearance:
0.160 to 0.342 mm (0.0063 to 0.0135 in.)
Maximum thrust clearance:
0.342 mm (0.0135 in.)
If the thrust clearance is greater than maximum, re-
place the connecting rod.
If necessary, replace the crankshaft.
3. INSPECT CONNECTING ROD OIL CLEARANCE
NOTICE:
Do not turn the crankshaft.
(a) Using marking paint, write the matched cylinder number
on each connecting rod and cap.
HINT:
The match marks on the connecting rods and caps are for ensuring correct reassembly.
SST
2004 COROLLA (RM1037U)
(b) Using SST, remove the 2 bolts and connecting rod cap.
SST 09205–16010
(c) Clean the crank pin and bearing.
(d) Check the cran k pin and bearing for pitting and scratches.
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–ENGINE MECHANICAL CYLINDER BLOCK ASSY (April, 2003)
Plastigage
Front Mark
SST
(e) Lay a strip of the Plastigage across the crank pin.
A01159
(f) Check that the front mark of the connecting rod cap is fac-
ing the correct direction.
(g) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
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(h) Using SST, tighten the bolts in several passes b y the spe-
cified torque.
SST 09205–16010
Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf)
Engine
Front
Paint Mark
SST
90
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(i) Mark the front of the connecting cap bolts with paint.
(j) Retighten the c a p b o lts b y 9 0 as shown in the illustration.
(k) Check that the crankshaft turns smoothly.
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(l) Remove the 2 bolts and connecting rod cap.
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Mark
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–ENGINE MECHANICAL CYLINDER BLOCK ASSY (April, 2003)
(m) Measure the Plastigage at its widest point.
Standard oil clearance:
0.028 to 0.060 mm (0.0011 to 0.0024 in.)
Maximum oil clearance: 0.080 mm (0.0031 in.)
NOTICE:
Remove the Plastigage completely after the measurement.
If the oil clearance is greater than maximum, re-
place the connecting rod bearing.
If necessary, grind or replace the crankshaft.
HINT:
If replacing a bearing, select a new one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked ”1”, ”2” and ”3” accordingly.
Item Mark mm (in.)
Connecting rod large end
bore diameter
Connecting rod bearing
thickness
Crankshaft pin outer diameter
1
2
3
1
2
3
– 43.992 to 44.000 (1.7320 to 1.7323)
47.000 to 47.008 (1.8504 to 1.8507)
47.009 to 47.016 (1.8507 to 1.8510)
47.017 to 47.024 (1.8511 to 1.8513)
1.486 to 1.490 (0.0585 to 0.0587)
1.491 to 1.494 (0.0587 to 0.0588)
1.495 to 1.498 (0.0589 to 0.0590)
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4. REMOVE CONNECTING ROD SUB–ASSY
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:
Keep the bearing, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in the
correct order.
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–ENGINE MECHANICAL CYLINDER BLOCK ASSY (April, 2003)
5. REMOVE CONNECTING ROD BEARING
(a) Remove the connecting rod bearing from the connecting
rod cap.
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(b) Remove the connecting rod bearing from the connecting
rod.
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Piston Ring
Expander
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6. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
7. REMOVE W/PIN PISTON SUB–ASSY
(a) Using a small screwdriver, pry out the 2 snap rings.
2004 COROLLA (RM1037U)
(b) Heat the piston to 80 to 90C (176 to 194F).
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–ENGINE MECHANICAL CYLINDER BLOCK ASSY (April, 2003)
(c) Using a plastic hammer and brass bar, lightly tap out the
piston pin, then remove the connecting rod.
HINT:
The piston and pin are a matched set.
Arrange the piston, pin, ring, connecting rod and bearings
in the correct order.
8. REMOVE CRANKSHAFT
(a) Remove the 10 bolts.
7 93
4 8 10 6 2
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(b) Uniformly loosen the 10 bearing cap bolts, in several
passes, in the sequence shown in the illustration.
SST 09011–38121
15
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(c) Using a screwdriver, remove the bearing cap by prying
the indicated portions between the cylinder block and
bearing cap.
NOTICE:
Be careful not to damage the contact surfaces of the cylinder block and bearing cap.
2004 COROLLA (RM1037U)
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–ENGINE MECHANICAL CYLINDER BLOCK ASSY (April, 2003)
(d) Remove the crankshaft from the cylinder block.
9. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.04 to 0.24 mm (0.0016 to 0.0094 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum,
measure the thrust washer thickness.
If the thickness is not specified, replace the thrust
washer.
HINT:
Thrust washer thickness: 2.430 to 2.480 mm (0.0957 to 0.0976
in.).
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10. REMOVE CRANKSHAFT THRUST WASHER UPPER
(a) Remove the 2 crankshaft thrust washers from the cylinder
block.
11. REMOVE CRANKSHAFT BEARING
(a) Remove the 5 crankshaft bearings from the cylinder
block.
NOTICE:
Arrange the main bearings and thrust washers in the correct order.
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–ENGINE MECHANICAL CYLINDER BLOCK ASSY (April, 2003)
(b) Remove the 5 crankshaft bearings from the bearing cap.
NOTICE:
Arrange the main bearings and thrust washers in the correct order.
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12. REMOVE STUD BOLT
(a) Using torx socket wrench E5 and E7, remove the 9 stud
bolts.
Intake Side: Upper Side:
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Bearing Cap Lower Side:
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