Part 1

CYLINDER BLOCK ASSY (1NZ-FE)(From April, 2004)
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: 0.16 to 0.36 mm (0.0063 to 0.0142 inch)
Maximum thrust clearance: 0.36 mm (0.0142 inch)
If the thrust clearance is greater than maximum, replace the connecting rod.
2. INSPECT CONNECTING ROD OIL CLEARANCE
a. Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly.





b. Using SST, remove the 2 connecting rod cap bolts.
SST 09205-16010
c. Clean the crank pin and bearing.
d. Check the crank pin and bearing for Fittings and scratches.





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





f. Match together the connecting rod and cap in the correct combination. Then install the cap onto the connecting rod, making sure that the front mark on the cap is correctly oriented.
g. Apply a light coat of engine oil to the threads of the connecting rod cap bolts.





h. Using SST, tighten the bolts in several steps to the specified torque.
SST 09205-16010
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)

NOTICE: Do not turn the crankshaft.





i. Mark the front of the connecting cap bolts with paint.
j. Retighten the cap bolts by 90° as shown in the illustration.

NOTICE: Do not turn the crankshaft.

k. Remove the 2 bolts, connecting rod cap and lower bearing.





l. Measure the Plastigage at its widest point.
Standard oil clearance: 0.016 to 0.040 mm (0.0006 to 0.0016 inch)
Maximum oil clearance: 0.06 mm (0.0024 inch)

NOTICE: Completely remove the Plastigage.





m. If the width is greater than maximum, select and replace the bearing. If necessary, use the undersize bearing.





HINT





3. REMOVE PISTON SUB-ASSY W/ CONNECTING ROD
a. Using a ridge reamer, remove all 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.
^ Keep the piston and the connecting rod assemblies in the correct order so they can be returned to the original locations when reassembling.

4. REMOVE CONNECTING ROD BEARING





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: 0.09 to 0.19 mm (0.0035 to 0.0075 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. Check the crankshaft and block for wear and repair or replace if necessary.

HINT: Thrust washer thickness is 2.43 to 2.48 mm (0.0957 to 0.0976 inch).





6. REMOVE CRANKSHAFT
a. Using several steps, uniformly loosen and remove the 10 bearing cap sub-assembly bolts with SST in the sequence shown in the illustration.
SST 09011-38121
b. Remove the bearing cap and crankshaft.
7. REMOVE CRANKSHAFT BEARING
8. REMOVE PISTON RING SET

HINT: Keep the piston rings in the correct combination and correct order so they can be returned to the original locations when reassembling.





a. Using a piston ring expander, remove the 2 compression rings.
b. Remove the 2 side rails and oil ring by hand.





9. REMOVE W/ PIN PISTON SUB-ASSY
a. Using SST, press out the piston pin from the piston.
SST 09221-25026 (09221-00021, 09221-00030, 09221-00190, 09221-00141, 09221-00150)

NOTICE: Keep the pistons, pins, rings, connecting rods and bearings in the correct order so they can be returned to the original locations when reassembling.

10. REMOVE CYLINDER BLOCK WATER DRAIN COCK PLUG
11. REMOVE STUD BOLT
a. Using Torx socket wrench E5, remove the 6 stud bolts.
12. REMOVE STRAIGHT PIN