Part 1

CYLINDER BLOCK ASSEMBLY (2AZ-FE)
OVERHAUL





1. CHECK 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 0.362 mm (0.0063 to 0.0143 inch)
Maximum thrust clearance: 0.362 mm (0.0143 inch)
- If the thrust clearance is greater than maximum, replace the connecting rod.
- If necessary, replace the crankshaft.
2. CHECK CONNECTING ROD OIL CLEARANCE

NOTICE: Do not turn the crankshaft during the measurement.

a. Using marking paint, write the matched cylinder number on each connecting rod and cap.

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





b. Using a 12 mm socket wrench, remove the 2 bolts and connecting rod cap.
c. Clean the crank pin and bearing.
d. Check the crank pin and bearing for pitting and scratches.





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





f. Check that the front mark of the connecting rod cap is facing in the correct direction.
g. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
h. Using a 12 mm socket wrench, tighten the bolts in several passes to the specified torque.
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)





i. Mark the front of the connecting rod bolts with paint.
j. Retighten the cap bolts 90° as shown in the illustration.
k. Check that the crankshaft turns smoothly.
l. Using a 12 mm socket wrench, remove the 2 bolts and connecting rod cap.





m. Measure the Plastigage at its widest point.
Standard oil clearance: 0.024 to 0.048 mm (0.0009 to 0.0019 inch)
Maximum oil clearance: 0.08 mm (0.0032 inch)

NOTICE: Remove the Plastigage completely after the measurement.

- If the oil clearance is greater than maximum, replace the connecting rod bearing.
- If necessary, grind or replace the crankshaft.








HINT: If replacing a bearing, select a new one with the same number as marked on the connecting rod. There are 3 sizes of standard bearings. marked "1", "2" and "3" accordingly.





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





5. REMOVE PISTON RING SET
a. Using a piston ring expander, remove the 2 compression rings.
b. Remove the 2 side rails and expander by hand.





6. REMOVE PISTON PIN HOLE SNAP RING
a. Using a small screwdriver, pry out the 2 snap rings.





7. REMOVE PISTON
a. Gradually heat the piston up to 80 to 90°C (176 to 194°F).





b. 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. CHECK 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 0.0095 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than maximum, replace the thrust washers as a set.

HINT: The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 inch).





9. REMOVE CRANKSHAFT
a. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
b. Remove the 5 bearing caps from the cylinder block.
c. Remove the crankshaft from the cylinder block.
10. REMOVE CRANKSHAFT THRUST WASHER UPPER
11. REMOVE CRANKSHAFT BEARING

HINT: Arrange the bearings in the correct order.

12. REMOVE CRANKSHAFT BEARING NO.2

HINT: Arrange the bearings in the correct order.