G16E-GTS (ENGINE MECHANICAL): CYLINDER BLOCK: DISASSEMBLY; 2023 - 2025 MY GR Corolla [11/2022

Last Modified: 05-13-2024	6.11:8.1.0	Doc ID: RM1000000028LLX
Model Year Start: 2023	Model: GR Corolla	Prod Date Range: [11/2022 - ]
Title: G16E-GTS (ENGINE MECHANICAL): CYLINDER BLOCK: DISASSEMBLY; 2023 - 2025 MY GR Corolla [11/2022 - ]

DISASSEMBLY

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during cylinder block removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
*1:w/ Steering Lock Function
Replacement of ECM	Perform Vehicle Identification Number (VIN) or frame number registration	MIL illuminates
	ECU configuration	-
	Update ECU security key	Vehicle Control History (RoB) are stored
	Heavy Knock History	-
	ECU communication ID registration (Immobiliser system)	Engine start function
	Code registration (Smart Key System (for Gasoline Model, Start Function))	Wireless Door Lock Control System (for Gasoline Model with Smart Key System) Smart Key System (for Gasoline Model, Entry Function) Smart Key System (for Gasoline Model, Start Function) Steering lock function*1
Replacement of throttle body with motor assembly Cleaning the deposits from the throttle body with motor assembly Replacement of engine assembly Replacement of cylinder head sub-assembly Replacement of camshaft (for intake or exhaust camshaft) Replacement of camshaft timing gear assembly Replacement of camshaft timing exhaust gear assembly Replacement of fuel pump assembly (for high pressure side) Replacement of fuel pressure sensor (for high pressure side) Replacement of air fuel ratio sensor Replacement of engine coolant temperature sensor Replacement of spark plug Replacement of ignition coil assembly Replacement of knock control sensor Replacement of turbocharger sub-assembly Gas leaks from exhaust system is repaired Replacement of piston or piston ring	Inspection After Repair	Poor idle, etc. Engine start function, etc.
Front wheel alignment adjustment	Perform "Reset Memory" Perform "Calibration"	VSC is disabled or malfunctions DTCs are output Slip indicator light illuminates ABS warning light illuminates
Tire	ECU Data Initialization (When performing tire replacement after RoB code X2104 is output)	Active Torque Split AWD System

NOTICE:

This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click here

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when vehicle is driven

Effect/Inoperative Function When Necessary Procedures are not Performed	Necessary Procedures	Link
Front Camera System	Drive the vehicle straight ahead at 35 km/h (22 mph) or more for 5 seconds or more.

Learning completes when vehicle is operated normally

Effect/Inoperative Function When Necessary Procedures are not Performed	Necessary Procedures	Link
Power door lock control system Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.

PROCEDURE

1. REMOVE NO. 1 VENTILATION CASE

CAUTION:

Do not diassembly except if the No. 1 ventilaion case to be damaged.

(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.

2. REMOVE NO. 1 CYLINDER BLOCK INSULATOR

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

3. 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:

0.15 to 0.50 mm (0.00591 to 0.0197 in.)

Maximum Thrust Clearance:

0.50 mm (0.0197 in.)

HINT:

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

4. INSPECT CONNECTING ROD OIL CLEARANCE

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

*a	Alignment Mark

(b) Using an E12 TORX soket wrench, remove the 2 connecting rod bolts and connecting rod bearing cap.

SST: 09205-16011

HINT:

Keep the connecting rod bearing and connecting rod bearing cap together.

(d) 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.

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

*a	Plastigage

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

*a	Front Mark

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

(h) Using an E12 TORX socket wrench, install and alternately tighten the 2 connecting rod bolts in several steps.

SST: 09205-16011

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

(i) Mark the front of each connecting rod bolt with paint.

*a	Paint Mark
*b	90°
	Front of Engine

(j) Tighten the connecting rod bolts 90° as shown in the illustration.

NOTICE:

Do not turn the crankshaft during the measurement.

(k) Remove the 2 connecting rod bolts and connecting rod bearing cap.

HINT:

Keep the connecting rod bearing and connecting rod bearing cap together.

(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.)

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 bearing 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	51.008 to 51.016 mm (2.00818 to 2.00850 in.)
3	51.016 to 51.024 mm (2.00850 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	1.491 to 1.495 mm (0.0587 to 0.0589 in.)
3	1.495 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.)

NOTICE:

Remove the Plastigage completely after the measurement.

*a	Plastigage
*b	1, 2 or 3 Mark

(m) Perform the inspection above for each cylinder.

5. REMOVE PISTON WITH CONNECTING ROD

(a) Using a ridge reamer, remove all the carbon from the top of each cylinder.

(b) Remove the 6 connecting rod bolts, 3 connecting rod bearing caps and 3 connecting rod bearings.

(c) Push the 3 pistons, 3 connecting rods and 3 connecting rod bearings out through the top of the cylinder block sub-assembly.

HINT:

Keep the connecting rod bearings, connecting rods and connecting rod bearing caps together.
Arrange the removed parts in such a way that they can be reinstalled to their original locations.

6. REMOVE CONNECTING ROD BEARING

(a) Remove the 6 connecting rod bearings from the 3 connecting rods and 3 connecting rod bearing caps.

HINT:

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

7. INSPECT CRANKSHAFT THRUST CLEARANCE

(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.)

8. REMOVE CRANKSHAFT

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

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

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.

HINT:

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

(d) Check each crankshaft journal and crankshaft bearing for pitting and scratches.

HINT:

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

9. REMOVE CRANKSHAFT THRUST WASHER

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

10. REMOVE CRANKSHAFT BEARING

(a) Remove the 4 No. 1 crankshaft bearings and 4 No. 2 crankshaft bearings from the cylinder block sub-assembly and crankshaft bearing cap.

HINT:

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

11. REMOVE PISTON RING SET

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

*a	Piston Ring Expander

(b) 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.

12. REMOVE PISTON PIN HOLE SNAP RING

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

HINT:

Tape the screwdriver tip before use.

*a	Front Mark Cutout Portion
*b	Protective Tape

13. REMOVE PISTON

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

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.

14. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

(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.

15. REMOVE NO. 2 OIL NOZZLE 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.

16. REMOVE NO. 3 OIL NOZZLE 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.

17. REMOVE STUD BOLT

NOTICE:

If a stud bolt is deformed or its threads are damaged, replace it.

(a) Using an E8 "TORX" socket wrench, remove the 7 stud bolts.