2000 TOYOTA CAMRY engine

A06590
A06589
A06587
A01774
A01775
EM±96
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1268 Author: Date:
20. 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.
21. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the No.1 and No.2
piston rings.
(b) Remove the 2 side rails and oil ring expander by hand.
HINT:
Arrange the piston rings in correct order only.
22. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to 80 ± 90°C (176 ± 194°F).
(c) Using a plastic±faced hammer and brass bar, lightly tap
out the piston pin and remove the connecting rod.
HINT:

The piston and pin are a matched set.

Arrange the pistons, pins, rings, connecting rods and
bearings in the correct order.

EM08J±03
S05970
Z19127
S05987
S05569
No.1 No.2 No.3 No.4Mark 1, 2 or 3
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±97
1269 Author: Date:
INSPECTION
1. CLEAN CYLINDER BLOCK
(a) Remove the gasket material.
Using a gasket scraper, remove all the gasket material
from the top surface of the cylinder block.
(b) Clean the cylinder block.
Using a soft brush and solvent, thoroughly clean the cylin-
der block.
2. INSPECT CYLINDER BLOCK
(a) Inspect for flatness.
Using a precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder head gasket for
warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder block.
(b) Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 4 cylinders and re-
place all the 4 pistons. (See page EM±104) If necessary, re-
place the cylinder block.
(c) Inspect the cylinder bore diameter.
HINT:
There are 3 sizes of the standard cylinder bore diameter,
marked º1º, º2º and º3º accordingly. The mark is stamped on the
top of the cylinder block.

Z19307
FrontThrust
Direction
Axial
Direction
10 mm
(0.39 in.)
10 mm
(0.39 in.)
A
C
B
1
21
2
S05989
Ridge Reamer
A06591
A06592
EM±98
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1270 Author: Date:
Using a cylinder gauge, measure the cylinder bore diame-
ter at positions A, B and C in the thrust and axial direc-
tions.
Standard diameter:
Mark º1º87.000 ± 87.010 mm (3.4252 ± 3.4256 in.)
Mark º2º87.010 ± 87.020 mm (3.4256 ± 3.4262 in.)
Mark º3º87.020 ± 87.030 mm (3.4260 ± 3.4264 in.)
Maximum diameter:
STD87.23 mm (3.4342 in.)
O/S 0.5087.73 mm (3.4350 in.)
If the diameter is greater than maximum, rebore all the 4 cylin-
ders and replace all the 4 pistons. (See page EM±104) If neces-
sary, replace the cylinder block.
(d) Remove the cylinder ridge.
If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.
3. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.

A06593
A07350
Mark 1, 2 or 3
Front
Mark
(Cavity)
A07352
20.5 mm
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±99
1271 Author: Date:
(c) Using solvent and a brush, thoroughly clean the piston.
NOTICE:
Do not use a wire brush.
4. INSPECT PISTON AND CONNECTING ROD
(a) Inspect the piston oil clearance.
HINT:
There are 3 sizes of the standard piston diameter, marked º1º,
º2º and º3º accordingly. The mark is stamped on the piston top.
(1) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, 20.5 mm
(0.807 in.) from the piston head.
Piston diameter:
STD Mark º1º
Mark º2º
Mark º3º86.815 ± 86.825 mm (3.4179 ± 3.4183 in.)
86.825 ± 86.835 mm (3.4183 ± 3.4186 in.)
86.835 ± 86.845 mm (3.4186 ± 3.4190 in.)
O/S 0.5087.315 ± 87.345 mm (3.4375 ± 3.4387 in.)
(2) Measure the cylinder bore diameter in the thrust
directions. (See step 2)
(3) Subtract the piston diameter measurement from the
cylinder bore diameter measurement.
Standard oil clearance:
0.175 ± 0.195 mm (0.0068 ± 0.0076 in.)
Maximum oil clearance: 0.215 mm (0.0085 in.)
If the oil clearance is greater than maximum, replace all the 4
pistons and rebore all the 4 cylinders. (See page EM±104) If
necessary, replace the cylinder block.

S05569A07350A07397
Mark 1, 2 or 3Mark 1, 2 or 3
No.1No.2 No.3No.4
A07348
A01916
110 mm
EM7639
EM±100
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1272 Author: Date:
HINT:
Use new cylinder block:
Use a piston with the same number mark as the cylinder bore
diameter marked on the cylinder block.
(b) Inspect the piston ring groove clearance.
Using a feeler gauge, measure the clearance between
new piston ring and the wall of the ring groove.
Ring groove clearance (No.1, No.2):
0.030 ± 0.070 mm (0.0012 ± 0.0028 in.)
If the clearance is not as specified, replace the piston.
(c) Inspect the piston ring end gap.
(1) Insert the piston ring into the cylinder bore.
(2) Using a piston, push the piston ring a little beyond
the bottom of the ring travel, 110 mm (4.33 in.) from
the top of the cylinder block.
(3) Using a feeler gauge, measure the end gap.
Standard end gap:
No.10.270 ± 0.490 mm (0.0106 ± 0.0192 in.)
No.20.450 ± 0.670 mm (0.0177 ± 0.0263 in.)
Oil (Side rail)0.100 ± 0.470 mm (0.0039 ± 0.0185 in.)
Maximum end gap:
No.11.09 mm (0.0429 in.)
No.21.27 mm (0.0499 in.)
Oil (Side rail)1.07 mm (0.0421 in.)

A06594
Z00064
Z00065
EM7538
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±101
1273 Author: Date:
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, rebore all the 4 cylinders (see page EM±104) or replace
the cylinder block.
(d) Inspect the piston pin fit.
At 60°C (140°F), you should be able to push the piston
pin into the piston pin hole with your thumb.
(e) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bend is greater than maximum, replace the connecting rod as-
sembly.
(2) Check for twist
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
(f) Inspect the piston pin oil clearance.
(1) Using a caliper gauge, measure the inside diameter
of the connecting rod bushing.
Bushing inside diameter:
22.005 ± 22.017 mm (0.8663 ± 0.8668 in.)

EM0227
P13428
A02826
15 mm
(0.59 in.)
EM±102
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1274 Author: Date:
(2) Using a micrometer, measure the piston pin diame-
ter.
Piston pin diameter:
21.997 ± 22.009 mm (0.8660 ± 0.8665 in.)
(3) Subtract the piston pin diameter measurement from
the bushing inside diameter measurement.
Standard oil clearance:
0.005 ± 0.011 mm (0.0002 ± 0.0004 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, replace the bush-
ing. (See page EM±104) If necessary, replace the piston and
piston pin as a set.
(g) Inspect the connecting rod bolts.
(1) Install the cap nut to the connecting rod bolt. Check
that the cap nut can be turned easily by hand to the
end of the thread.
(2) If the cap nut cannot be turned easily, measure the
outside diameter of the connecting rod bolt with a
vernier caliper.
Standard diameter:
7.860 ± 8.000 mm (0.3094 ± 0.3150 in.)
Minimum diameter: 7.60 mm (0.2992 in.)
HINT:
If the location of this area cannot be judged by visual inspection,
measure the outer diameter at the location shown in the illustra-
tion.
If the outside diameter is less than minimum, replace the con-
necting rod bolt and nut as a set.

P00118
EM3553
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±103
1275 Author: Date:
5. INSPECT CRANKSHAFT
(a) Inspect for circle runout.
(1) Place the crankshaft on V±blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
(b) Inspect the main journals and crank pins.
(1) Using a micrometer, measure the diameter of each
main journal and crank pin.
Main journal diameter:
STD54.988 ± 55.003 mm (2.1653 ± 2.1655 in.)
U/S 0.2554.745 ± 54.755 mm (2.1553 ± 2.1557 in.)
Crank pin diameter:
STD51.985 ± 52.000 mm (2.0466 ± 2.0472 in.)
U/S 0.2551.745 ± 51.755 mm (2.0372 ± 2.0376 in.)
If the diameter is not as specified, check the oil clearance. (See
page EM±86) If necessary, grind or replace the crankshaft.
(2) Check each main journal and crank pin for taper
and out±of±round as shown.
Maximum taper and out±of±round:
0.02 mm (0.0008 in.)
If the taper and out±of±round is greater than maximum, replace
the crankshaft.
6. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the fin-
ished undersized diameter. (See procedure in step 5) Install
new main journal and/or crankshaft pin undersized bearings.