Part 2

CYLINDER BLOCK ASSEMBLY (2AZ-FE)
OVERHAUL
13. REMOVE STUD BOLT
a. Remove the 8 stud bolts.





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





15. INSPECT CYLINDER BORE
a. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
Standard diameter: 88.500 to 88.513 mm (3.4843 to 3.4848 inch)
Maximum diameter: 88.633 mm (3.4895 inch)
If the average diameter of the 4 positions is greater than maximum, replace the cylinder block.





16. INSPECT PISTON
a. Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at the piston 30.3 mm (1.193 inch) from the piston head.
Piston diameter: 88.439 to 88.449 mm (3.4819 to 3.4822 inch)
If the diameter is not as specified, replace the piston.
17. CHECK PISTON OIL CLEARANCE
a. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.051 to 0.074 mm (0.0020 to 0.0029 inch)
Maximum oil clearance: 0.10 mm (0.0039 inch)
- If the oil clearance is greater than maximum, replace all the pistons.
- If necessary, replace the cylinder block.





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





Ring groove clearance

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





19. CHECK PISTON RING END GAP
a. 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.





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





Standard end gap





Maximum gap

- 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.





20. CHECK PISTON PIN OIL CLEARANCE





a. Using a caliper gauge, measure the piston pin bore diameter.
Piston pin bore diameter: 22.001 to 22.010 mm (0.8662 to 0.8665 inch)
If the diameter is not as specified, replace the piston.





b. Using a micrometer, measure the piston pin outer diameter.





Piston pin outer diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 inch)
If the diameter is not as specified, replace the piston pin.





c. Using a caliper gauge, measure the connecting rod small end bore diameter.





Connecting rod small end bore diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 inch)
If the diameter is not as specified, replace the connecting rod.





d. Subtract the piston pin outer diameter measurement from the piston pin bore diameter measurement.
Standard oil clearance: 0.001 to 0.007 mm (0.00004 to 0.0003 inch)
Maximum oil clearance: 0.013 mm (0.0005 inch)
- If the oil clearance is greater than maximum, replace the connecting rod.
- If necessary, replace the piston and piston pin as a set.
e. Subtract the piston pin outer diameter measurement from the connecting rod small end bore diameter measurement.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 inch)
Maximum oil clearance: 0.017 mm (0.0007 inch)
- If the oil clearance is greater than maximum, replace the connecting rod.
- If necessary, replace the connecting rod and piston pin as a set.





21. INSPECT CONNECTING ROD SUB-ASSEMBLY
a. Using a connecting rod aligner and feeler gauge, check the connecting rod alignment.
1. Check for misalignment.
Maximum misalignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If the misalignment is greater than maximum, replace the connecting rod.





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





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





23. INSPECT CRANKSHAFT
a. Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration.
Maximum circle runout: 0.03 mm (0.0012 inch)
If the circle runout is greater than maximum, replace the crankshaft.





b. Using a micrometer, measure the diameter of each main journal.
Diameter: 54.988 to 55.000 mm (2.1649 to 2.1654 inch)
If the diameter is not as specified, check the crankshaft oil clearance.
c. Check each main journal for taper and distortion as shown in the illustration.
Maximum taper and distortion: 0.003 mm (0.0001 inch)
If the taper and distortion are greater than maximum, replace the crankshaft.





Diameter (Reference)





d. Using a micrometer, measure the diameter of each crank pin.
Diameter: 47.990 to 48.000 mm (1.8894 to 1.8898 inch)
If the diameter is not as specified, check the connecting rod oil clearance.
e. Check each crank pin for taper and distortion as shown in the illustration.
Maximum taper and distortion: 0.003 mm (0.0001 inch)
If the taper and distortion are greater than maximum, replace the crankshaft.





24. INSPECT CRANKSHAFT BEARING CAP SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolts.
Standard diameter: 7.5 to 7.6 mm (0.295 to 0.299 inch)
Minimum diameter: 7.5 mm (0.295 inch)
If the diameter is less than minimum, replace the bolt.