Part 1

CYLINDER BLOCK ASSEMBLY (2TR-FE)

COMPONENTS

OVERHAUL

1. 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: 0.150 to 0.350 mm (0.0059 to 0.0138 inch)
Maximum thrust clearance: 0.40 mm (0.016 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE
a. Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly.

HINT: The matchmarks on the connecting rods and caps are for ensuring the correct reassembly.

b. Remove the 2 connecting rod cap bolts.
c. 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.

HINT: Keep the lower bearing inserted to the connecting rod cap.

d. Clean the crank pin and bearing.
e. Check the crank pin and bearing for pitting and scratches.

f. Lay a strip of Plastigage on the crank pin.

g. Check that the front mark of the connecting rod cap is facing forward.

h. Install the connecting rod cap. (see step 51)

NOTICE: Do not turn the crankshaft.

i. Remove the 2 bolts and connecting rod cap (see steps (b) and (c) above).

j. Measure the Plastigage at its widest point.
Standard oil clearance: 0.024 to 0.049 mm (0.0009 to 0.0019 inch)
Maximum oil clearance: 0.066 mm (0.0026 inch)
If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, replace the crankshaft.

HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2 and 3 mark on its surface.

Reference: Crankshaft pin diameter

Standard bearing center wall thickness

k. Completely remove the Plastigage.

3. REMOVE PISTON SUB-ASSEMBLY W/CONNECTING ROD
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.

4. REMOVE CONNECTING ROD BEARING

HINT: Arrange the removed parts in the correct order.

5. 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: 0.020 to 0.220 mm (0.0008 to 0.0087 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.
Thrust washer thickness: 2.440 to 2.490 mm (0.0961 to 0.0980 inch)

6. REMOVE CRANKSHAFT
a. Uniformly loosen the 10 bearing cap bolts, in several steps, in the sequence shown in the illustration.

HINT:
- Keep the lower bearings and crankshaft bearing caps together.
- Arrange the thrust washers in the correct order.

b. Lift out the crankshaft.

c. Remove the upper bearings and upper thrust washers from the cylinder block.

HINT: Arrange the main bearing caps, bearings and thrust washers in the correct order.

7. REMOVE CRANKSHAFT BEARING

HINT: Arrange the removed parts in the correct order.

8. REMOVE PISTON RING SET
a. Using a piston ring expander, remove the 2 compression rings.
b. Using a piston ring expander, remove the oil ring rail.
c. Remove the oil ring expander by hand.

HINT: Arrange the piston rings in the correct order.

9. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Remove the water drain cock sub-assembly from the cylinder block.
b. Remove the water drain cock plug from the water drain cock sub-assembly.

10. REMOVE W/PIN PISTON SUB-ASSEMBLY
a. Check the fitting condition between the piston and piston pin.
(1) 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.

b. Disconnect the connecting rod from the piston.
(1) Using a screwdriver, pry off the snap rings from the piston.

(2) Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).

(3) Using a brass bar and plastic-faced hammer, lightly tap out the piston pin and remove the connecting rod.

HINT:
- The piston and pin are a matched set.
- Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

11. CLEAN W/PIN PISTON SUB-ASSEMBLY
a. Using a gasket scraper, remove the carbon from the piston top.

b. Using a groove cleaning tool or broken ring, clean the piston ring grooves.

c. Using solvent and a brush, thoroughly clean the piston.

NOTICE: Do not use a wire brush.

12. REMOVE SUB-ASSEMBLY OIL NOZZLE NO.1
a. Using a 5 mm hexagon wrench, remove the oil nozzles.
13. INSPECT SUB-ASSEMBLY OIL NOZZLE NO.1
a. Check the oil nozzles for damage or clogging. If necessary, replace the oil nozzle.

14. INSPECT BALANCE SHAFT THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
Standard thrust clearance: 0.07 to 0.13 mm (0.0027 to 0.0051 inch)
Maximum thrust clearance: 0.20 mm (0.0079 inch)
If the thrust clearance is greater than the maximum, replace the balance shaft thrust washer. If necessary, replace the balance shaft.

15. REMOVE NO.1 BALANCE SHAFT
a. Remove the bolt.

b. Remove the balance shaft from the cylinder block.

NOTICE: When removing the balance shaft, make sure to support the balance shaft with both hands and avoid scratching the balance shaft bearing on the cylinder block side.

16. REMOVE BALANCE SHAFT DRIVEN GEAR NO.1
a. Mount the head portion of the balance shaft in a vise.

NOTICE: Be careful not to damage the balance shaft.

b. Remove the bolt.
c. Remove the balance shaft driven gear No.1 (* 1), sliding key (* 2), balance shaft thrust washer No.1 (* 3) and balance shaft thrust spacer (* 4).

17. REMOVE NO.2 BALANCE SHAFT
a. Remove the 2 bolts.

18. REMOVE BALANCE SHAFT DRIVEN GEAR NO.2
a. Mount the head portion of the balance shaft in a vise.

NOTICE: Be careful not to damage the balance shaft.

b. Remove the bolt.
c. Remove the balance shaft driven gear No.2 (* 1) and balance shaft thrust washer No.2 (* 2).

19. INSPECT CYLINDER BLOCK FOR FLATNESS
a. Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.
Maximum warpage: 0.05 mm (0.0020 inch)
If the warpage is greater than the maximum, replace the cylinder block.

b. Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 4 cylinders. If necessary, replace the cylinder block.

20. INSPECT CYLINDER BORE
a. Using a cylinder gauge, measure the cylinder bore diameter at positions A in the thrust and axial directions.
Standard diameter: 94.990 to 95.003 mm (3.7398 to 3.7403 inch)
Maximum difference diameter: 0.2 mm (0.008 inch)
If the diameter is greater than the maximum, rebore all the 4 cylinders. If necessary, replace the cylinder block.

b. Inspect the cylinder ridge.
If the wear is less than 0.2 mm (0.008 inch), using a ridge reamer, grind the top of the cylinder.

21. CLEAN CYLINDER BLOCK
a. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
b. Using a soft brush and solvent, thoroughly clean the cylinder block.

22. INSPECT PISTON DIAMETER
a. Using a micrometer, measure the piston diameter at right angles to the piston center line, the indicated distance from the piston end.
23. INSPECT PISTON OIL CLEARANCE
a. Measure the cylinder bore diameter in the thrust directions (see step 20).
b. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.019 to 0.052 mm (0.0007 to 0.0020 inch)
If the oil clearance is greater than the standard, replace all the pistons and rebore all the cylinders. If necessary, replace the cylinder block.

HINT:
- Bore all the cylinders for the O/S piston outside diameter.
- Replace all the piston rings with ones to match the O/S pistons.

c. If the oil clearance is greater than the standard.
(1) Prepare 4 new O/S pistons.
O/S 0.50 piston diameter: 95.441 to 95.451 mm (3.7575 to 3.7579 inch)
(2) Using a micrometer, measure the piston diameter at right angles to the piston center line, the indicated distance from the piston end.
Distance: 9.3 mm (0.366 inch)
(3) Calculate the amount each cylinder is to be rebored as follows:
Size to be rebored = P + C - H
P = Piston diameter
C = Piston clearance: 0.019 to 0.052 mm (0.0007 to 0.0020 inch)
H = Allowance for honing: 0.02 mm (0.0008 inch) or less
(4) Bore and hone the cylinders to calculated dimensions.
Maximum honing: 0.02 mm (0.0008 inch)

NOTICE: Excess honing will destroy the finished roundness.

24. INSPECT RING GROOVE CLEARANCE
a. Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

Ring groove clearance

If the clearance is not as specified, replace the piston.

25. INSPECT PISTON RING END GAP
a. Insert the piston ring into the cylinder bore.
b. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 inch) from the top of the cylinder block.

c. Using a feeler gauge, measure the end gap.

Standard end gap

Maximum end gap

If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum, even with a new piston ring, rebore all the 4 cylinders or replace the cylinder block.

26. INSPECT PISTON PIN OIL CLEARANCE
a. Using a caliper gauge, measure the inside diameter of the piston pin hole.
Piston pin hole inside diameter: 22.001 to 22.010 mm (0.8662 to 0.8665 inch)

b. Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 inch)

c. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 inch)
d. Subtract the piston pin diameter measurement from the piton pin hole diameter measurement.
Standard oil clearance: 0.001 to 0.007 mm (0.00004 to 0.00028 inch)
Maximum oil clearance: 0.010 mm (0.0004 inch)

HINT: If the oil clearance is greater than the maximum, replace the piston and piston pin as a set.

e. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 inch)
Maximum oil clearance: 0.025 mm (0.0010 inch)
If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin as a set.

27. INSPECT CONNECTING ROD
a. Using a rod aligner and feeler gauge, check the connecting rod alignment.
(1) Check for bend.
Maximum bend: 0.03 mm (0.0012 inch) per 100 mm (3.94 inch)
If the bend is greater than the maximum, replace the connecting rod sub-assembly.

(2) Check for twist.
Maximum twist: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)
If the twist is greater than the maximum, replace the connecting rod sub-assembly.

28. REMOVE CONNECTING ROD SMALL END BUSH
a. Using SST and a press, press out the bush.
SST 09222-30010

29. INSPECT CONNECTING ROD BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 inch)
Minimum diameter: 7.0 mm (0.276 inch)
If the diameter is less than the minimum, replace the bolt.

30. INSPECT CRANKSHAFT
a. Inspect for circle runout.
(1) Place the crankshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.03 mm (0.0012 inch)
If the circle runout is greater than the maximum, replace the crankshaft.

b. Inspect the main journals.
(1) Using a micrometer, measure the diameter of each main journal.

Standard journal diameter

If the diameter is not as specified, check the oil clearance (see step 30). If necessary, replace the crankshaft.
(2) Check each main journal for taper and out-of-round as shown in the illustration.
Maximum taper and out-of-round: 0.005 mm (0.0002 inch)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.

c. Inspect the crank pin.
(1) Using a micrometer, measure the diameter of each crank pin.
Diameter: 52.989 to 53.002 mm (2.0862 to 2.0867 inch)
If the diameter is not as specified, check the oil clearance (see step 2). If necessary, replace the crankshaft.
(2) Check each crank pin for taper and out-of-round as shown in the illustration.
Maximum taper and out-of-round: 0.003 mm (0.0001 inch)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.