Page 1417 of 2543

(c) Lift out the crankshaft.
HINT: Keep the upper bearing and upper thrust washers to-
gether with the cylinder block.
(d) Clean each main journal and bearing.
(e) Ch e ck ea ch ma in jo u rn a l an d be a rin g fo r pittin g an d
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps.
(See step 5 in cylinder block installation)
Torque:
1st
44 NVm (450 kgfVcm, 33 ftVlbf)
2nd
Turn 90°
NOTICE: Do not turn the crankshaft.
(i) Remove the main bearing caps.
(See procedures (a) and (b) above)
(j) Measure the Plastigage at its widest point.
Standard clearance:
STD
.026±0.040 mm (0.0010±0.0016 in.)
U/S 0.25
.025±0.061 mm (0.0010±0.0024 in.)
Maximum clearance:
STD
.06 mm (0.0024 in.)
U/S 0.25
.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the
bearings. If necessary, grind or replace the crankshaft.
± ENGINEENGINE MECHANICALEG±103
Page 1418 of 2543

HINT: If using a standard bearing, replace with one having
the same number. If the number of the bearing cannot be de-
termined, select the correct bearing by adding together the
numbers imprinted on the cylinder block and crankshaft, then
refer to the table below for the appropriate bearing number.
There are 5 sizes of standard bearings, marked º1º, º2º, º3º,
º4º and º5º accordingly.
Total number º º:Number mark
Cylinder block (A)
+
02
35
68
911
12 14
+
Crankshaft (B) =
0±2
3±5
6±8
9±11
12±14
Use bearingº1ºº2ºº3ºº4ºº5ºUse bearingº1ºº2ºº3ºº4ºº5º
EXAMPLE: Cylinder block º3º (A)
+ Crankshaft º4º(B)
= Total number 7 (Use bearing º3º)
Reference:
Cylinder block main journal bore diameter (A):
Mark º0º
66.020±66.022 mm (2.59922±2.59929 in.)
Mark º1º
66.022±66.024 mm (2.59929±2.59936 in.)
Mark º2º
66.024±66.026 mm (2.59936±2.59944 in.)
Mark º3º
66.026±66.028 mm (2.59944±2.59952 in.)
Mark º4º
66.028±66.030 mm (2.59952±2.59960 in.)
Mark º5º
66.030±66.032 mm (2.59960±2.59968 in.)
Mark º6º
66.032±66.034 mm (2.59968±2.59976 in.)
Mark º7º
66.034±66.036 mm (2.59976±2.59984 in.)
Crankshaft main journal diameter (B):
Mark º0º
61.998±62.000 mm (2.44086±2.44094 in.)
Mark º1º
61.996±61.998 mm (2.44078±2.44086 in.)
Mark º2º
61.994±61.996 mm (2.44070±2.44078 in.)
Mark º3º
61.992±61.994 mm (2.44063±2.44070 in.)
Mark º4º
61.990±61.992 mm (2.44055±2.44063 in.)
Mark º5º
61.988±61.990 mm (2.44047±2.44055 in.) EG±104
± ENGINEENGINE MECHANICAL
Page 1419 of 2543

Mark º6º
61.986±61.988 mm (2.44039±2.44047 in.)
Mark º7º
61.984±61.986 mm (2.44031±2.44039 in.)
Bearing center wall thickness:
Mark º1º
1.994±1.997 mm (0.0785±0.0786 in.)
Mark º2º
1.997±2.000 mm (0.0786±0.0787 in.)
Mark º3º
2.000±2.003 mm (0.0787±0.0789 in.)
Mark º4º
2.003±2.006 mm (0.0789±0.0790 in.)
Mark º5º
2.006±2.009 mm (0.0790±0.0791 in.)
Standard sized Bearing Selection chart
Crankshaft Cylinder block number mark
number mark 0 1 2 3 4 5 6 7
011122233 011122233
111222333
111222333
212223334212223334 322233344322233344 422333444 422333444
523334455 523334455
633344555 633344555
733445555 733445555
EXAMPLE: Cylinder block º3º Crankshaft º4º
= Use bearing º3º
(k) Completely remove the Plastigage.
7. REMOVE CRANKSHAFT
(a) Lift out the crankshaft
(b) 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.
8. 2JZ±GTE:
REMOVE OIL NOZZLES (WITH RELIEF VALVES)
Using a 5 mm hexagon wrench, remove the bolt and oil
nozzle. Remove the 6 oil nozzles.
± ENGINEENGINE MECHANICALEG±105
Page 1420 of 2543

CYLINDER BLOCK INSPECTION
1. CLEAN CYLINDER BLOCK
A. Remove gasket material
Using a gasket scraper, remove all the gasket material from
the cylinder block surface.
B. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder
block.
2. INSPECT CYLINDER BLOCK SURFACE FOR FLATNESS
Using precision straight edge and feeler gauge, measure the
surfaces of the cylinder block for warpage.
Maximum warpage:
0.07 mm (0.0028 in.)
If warpage is greater than maximum, replace the cylinder
block.
3. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
4. INSPECT CYLINDER BORE DIAMETER
Using a cylinder gauge, measure the cylinder bore diameter
at positions A, B and C in the thrust and axial directions.
Standard diameter:
86.000±86.013 mm (3.3858±3.3863 in.)
Maximum diameter:
86.02 mm (3.3866 in.)
If the diameter is greater than maximum, replace the cylinder
block. EG±106
± ENGINEENGINE MECHANICAL
Page 1421 of 2543
5. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 in.), using a ridge ream-
er, grind the top of the cylinder.
6. INSPECT MAIN BEARING CAP BOLTS
Using vernier calipers, measure the minimum diameter of the
compressed thread at the measuring point.
Standard diameter:
9.96±9.97 mm (0.3921±0.3925 in.)
Minimum diameter:
9.7 mm (0.382 in.)
If the diameter is less than minimum, replace the bolt.
PISTON AND CONNECTING ROD
DISASSEMBLY
1. CHECK FIT BETWEEN PISTON AND PISTON PIN
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.
2. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring expander by hand.
HINT: Arrange the piston rings in correct order only.
3. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, remove the 2 snap rings.
± ENGINEENGINE MECHANICALEG±107
Page 1422 of 2543
(b) Gradually heat the piston to about 80°C (176°F).
(c) Using a plastic±faced hammer and brass bar, lightly tap out
the piston pin and remove the connecting rod.
HINT:
wThe piston and pin are a matched set.
wArrange the pistons, pins, rings, connecting rods and
bearings in the correct order.
PISTON AND CONNECTING ROD
INSPECTION
1. CLEAN PISTON
(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.
EG±108± ENGINEENGINE MECHANICAL
Page 1423 of 2543

2. INSPECT PISTON
A. Inspect piston oil clearance
(a) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 34 mm (1.34 in.) from the
piston head.
Piston diameter:
2JZ±GE
85.935±85.945 mm (3.3833±3.3837 in.)
2JZ±GTE
85.917±85.927 mm (3.3826±3.3830 in.)
(b) Measure the cylinder bore diameter in the thrust directions.
(See step 4 in cylinder block inspection)
(c) Subtract the piston diameter measurement from the cylinder
bore diameter measurement.
Standard oil clearance:
2JZ±GE
.055±0.078 mm (0.0022±0.0031 in.)
2JZ±GTE
.073±0.096 mm (0.0029±0.0038 in.)
Maximum oil clearance:
2JZ±GE
.10 mm (0.0039 in.)
2JZ±GTE
.12 mm (0.0047 in.)
If the oil clearance is greater than maximum, replace all the
6 pistons. If necessary, replace the cylinder block.
B. Inspect piston ring groove clearance
Using a feeler gauge, measure the clearance between new
piston ring and the wall of the piston ring groove.
Ring groove clearance:
No.1
2JZ±GE
0.011±0.070 mm (0.0004±0.0028 in.)
2JZ±GTE
0.040±0.080 mm (0.0016±0.0031 in.)
No.2
.030±0.070 mm (0.0012±0.0028 in.)
If the clearance is not as specified, replace the piston.
C. 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, 105 mm (4.13 in.) from the top of the cylinder
block.
± ENGINEENGINE MECHANICALEG±109
Page 1424 of 2543
(c) Using a feeler gauge, measure the ring end gap.
Standard ring end gap:
No.1
2JZ±GE
0.300±0.470 mm (0.0118±0.0185 in.)
2JZ±GTE
0.300±0.400 mm (0.0118±0.0157 in.)
No.2
2JZ±GE
0.350±0.520 mm (0.0138±0.0205 in.)
2JZ±GTE
0.350±0.450 mm (0.0138±0.0178 in.)
Oil (Side rail)
2JZ±GE
0.130±0.450 mm (0.0051±0.0177 in.)
2JZ±GTE
0.130±0.380 mm (0.0051±0.0150 in.)
Maximum ring end gap:
No.1
2JZ±GE
1.07 mm (0.0421 in.)
2JZ±GTE
1.00 mm (0.0394 in.)
No.2
2JZ±GE
1.12 mm (0.0441 in.)
2JZ±GTE
1.05 mm (0.0413 in.)
Oil (Side rail)
2JZ±GE
1.05 mm (0.0413 in.)
2JZ±GTE
0.98 mm (0.0386 in.)
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.
D. Inspect piston pin fit
At 80°C (176°F), you should be able to push the piston pin
into the piston pin hole with your thumb. EG±110
± ENGINEENGINE MECHANICAL