Part 3
CYLINDER BLOCK ASSEMBLY (2AZ-FE)
OVERHAUL
25. CHECK CRANKSHAFT OIL CLEARANCE
NOTICE: Do not turn the crankshaft during the measurement.
a. Clean each main journal and bearing.
b. Check each main journal and bearing for pitting and scratches.
c. Install the upper bearing with an oil groove onto the cylinder block.
NOTICE: Do not apply engine oil to the bearing or its contact surface.
d. Install the lower bearing onto the bearing cap.
NOTICE: Do not apply engine oil to the bearing or its contact surface.
e. Place the crankshaft onto the cylinder block.
f. Lay a strip of Plastigage across each journal.
g. Examine the front marks and numbers and install the bearing caps onto the cylinder block in the sequence order shown in the illustration.
h. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
i. Using several steps, uniformly Install and tighten the 10 bearing cap bolts in the sequence shown in the illustration.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
j. Mark the front of the bearing cap bolts with paint.
k. Retighten the bearing cap bolts 90° in the same sequence as step (i).
l. Check that the painted marks are at a 90° angle to the front.
m. Remove the bearing caps.
n. Measure the Plastigage at its widest point.
Standard oil clearance: 0.017 to 0.040 mm (0.0007 to 0.0016 inch)
Maximum oil clearance: 0.050 mm (0.0020 inch)
NOTICE: Remove the Plastigage completely after the measurement.
- If the oil clearance is greater than maximum, replace the crankshaft bearing.
- If necessary, replace the crankshaft.
HINT:
If replacing a bearing, select a new one with the same number.
If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft, then select a new bearing with the calculated number. There are 4 sizes of standard bearings marked "1", "2", "3" and "4" accordingly.
HINT:
EXAMPLE
Imprinted number on the cylinder block is 3
Imprinted number on the crankshaft is 4
3 + 4 = 7
Select the bearing marked "7"
26. INSTALL TIGHT PLUG
a. Apply adhesive around the new tight plugs.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent.
b. Using SST, install 2 tight plugs.
SST 09950-60010 (09951-00200), 09950-70010 (09951-07100)
Standard depth
27. INSTALL RING PIN
a. Using a plastic hammer, install 12 new ring pins.
Protrusion height
28. INSTALL STRAIGHT PIN
a. Using a plastic hammer, install 8 new straight pins.
Protrusion height
29. INSTALL STUD BOLT
a. Install 8 stud bolts into the cylinder block.
Torque
30. INSTALL PISTON
a. Using a small screwdriver, install a new snap ring onto one end of the piston pin hole.
HINT: Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
b. Gradually heat the piston up to 80 to 90°C (176 to 194°F).
c. Align the front marks of the piston and connecting rod, then push in the piston pin with your thumb until the pin comes into contact with the snap ring.
d. Using a small screwdriver, install a new snap ring onto other end of the piston pin hole.
HINT: Make sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
31. INSTALL PISTON RING SET
a. Install the expander and 2 side rails by hand.
b. Using a piston ring expander, install the 2 compression rings with the painted mark as shown in the illustration.
NOTICE: Install compression ring No. 2 with the code mark (2N) facing upward.
c. Position the piston rings so that the ring ends are as shown in the illustration.
32. INSTALL CRANKSHAFT BEARING
a. Install the upper bearing with an oil groove onto the cylinder block.
NOTICE: Do not apply engine oil to the bearing or its contact surface.
33. INSTALL CRANKSHAFT BEARING NO.2
a. Install the lower bearing onto the bearing cap.
NOTICE: Do not apply engine oil to the bearing or its contact surface.
34. INSTALL CRANKSHAFT THRUST WASHER UPPER
a. Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward.
35. INSTALL CRANKSHAFT
a. Apply engine oil to the upper bearing, and install the crankshaft onto the cylinder block.
b. Examine the front marks and numbers and install the bearing caps onto the cylinder block in the sequence order shown in the illustration.
c. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
d. Using several steps, uniformly Install and tighten the 10 bearing cap bolts in the sequence shown in the illustration.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
e. Mark the front of the bearing cap bolts with paint.
f. Retighten the bearing cap bolts 90° in the same sequence as step (d).
g. Check that the painted marks are now at a 90° angle to the front.
h. Check that the crankshaft turns smoothly.
36. INSTALL CONNECTING ROD BEARING
a. Align the bearing claw with the oil groove of the connecting rod or connecting rod cap.
NOTICE: Do not apply engine oil to the bearing or its contact surface.
37. INSTALL PISTON SUB-ASSEMBLY W/CONNECTING ROD
a. Apply engine oil to the cylinder walls, pistons, and surfaces of connecting rod bearings.
b. Check the position of the piston ring ends.
c. Using a piston ring compressor, correctly push the numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.
d. Check that the front mark of the connecting rod cap is facing in the correct direction.
NOTICE: Match the numbered connecting rod cap with the connecting rod.
e. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
f. 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.)
g. Mark the front of the connecting rod bolts with paint.
h. Retighten the cap bolts 90° as shown in the illustration.
i. Check that the crankshaft turns smoothly.