Page 1297 of 1897

P12734
Number MarkNo.3
Number
MarkNo.4 No.2
No.1
No.3
No.4 No.2
No.1
Number Mark
EXAMPLE: Cylinder block º06º (A)
+ Crankshaft º08º (B)
= Total number 14 (Use bearing º5º) No.1 and No.4 journal bearings
Cylinder block (A)
Crankshaft (B)+
Total number º º: Number mark
0 - 5 12 - 176 - 11 18 - 23 24 - 28
º3º º4º º5º º6º º7º Use bearing
EXAMPLE: Cylinder block º06º, Crankshaft º08º
= Use bearing º5º No.1 and No.4 journal standard bearings selection chart
Crankshaft
number markCylinder block number mark
00
01
02
03
04
05
06
07
08
09
10
11
1200 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16
4
5 3
3
3
3
3
3
4
4
4
4
43
3
3
3
3
4
4
4
4
4
4
5
53
3
3
3
4
4
4
4
4
4
5
5
53
3
3
4
4
4
4
4
4
5
5
5
53
3
4
4
4
4
4
4
5
5
5
5
53
4
4
4
4
4
4
5
5
5
5
5
54
4
4
4
4
4
5
5
5
5
5
5
64
4
4
4
4
5
5
5
5
5
5
6
64
4
4
4
5
5
5
5
5
5
6
6
64
4
4
5
5
5
5
5
5
6
6
6
64
4
5
5
5
5
5
5
6
6
6
6
64
5
5
5
5
5
5
6
6
6
6
6
65
5
5
5
5
5
6
6
6
6
6
6
75
5
5
5
5
6
6
6
6
6
6
7
75
5
5
5
6
6
6
6
6
6
7
7
75
5
5
6
6
6
6
6
6
7
7
7
75
5
6
6
6
6
6
6
7
7
7
7
7
- ENGINE MECHANICALCYLINDER BLOCK
EM-89
1073 Author: Date:
2001 AVALON (RM808U)
HINT:
If using a bearing, replace it with one having the same number.
If the number of the bearing cannot be determined, 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. The No.1 and No.4 journal
bearings have 5 standard bearing sizes, marked º3º, º4º, º5º, º6º
and º7º accordingly. The No.2 and No.3 journal bearings have
5 standard bearing sizes, marked º1º, º2º, º3º, º4º and º5º ac-
cordingly.
Page 1298 of 1897

EXAMPLE: Cylinder block º06º (A)
+ Crankshaft º08º (B)
= Total number 14 (Use bearing º3º) No.2 and No.3 journal bearings
Cylinder block (A)
Crankshaft (B)+
Total number º º: Number mark
0 - 5 12 - 176 - 11 18 - 23 24 - 28
º1º º2º º3º º4º º5º Use bearing
EXAMPLE: Cylinder block º06º, Crankshaft º08º
= Use bearing º3º No.2 and No.3 journal standard bearings selection chart
Crankshaft
number markCylinder block number mark
00
01
02
03
04
05
06
07
08
09
10
11
1200 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16
2
3 1
1
1
1
1
1
2
2
2
2
21
1
1
1
1
2
2
2
2
2
2
3
31
1
1
1
2
2
2
2
2
2
3
3
31
1
1
2
2
2
2
2
2
3
3
3
31
1
2
2
2
2
2
2
3
3
3
3
31
2
2
2
2
2
2
3
3
3
3
3
32
2
2
2
2
2
3
3
3
3
3
3
42
2
2
2
2
3
3
3
3
3
3
4
42
2
2
2
3
3
3
3
3
3
4
4
42
2
2
3
3
3
3
3
3
4
4
4
42
2
3
3
3
3
3
3
4
4
4
4
42
3
3
3
3
3
3
4
4
4
4
4
43
3
3
3
3
3
4
4
4
4
4
4
53
3
3
3
3
4
4
4
4
4
4
5
53
3
3
3
4
4
4
4
4
4
5
5
53
3
3
4
4
4
4
4
4
5
5
5
53
3
4
4
4
4
4
4
5
5
5
5
5 EM-90
- ENGINE MECHANICALCYLINDER BLOCK
1074 Author: Date:
2001 AVALON (RM808U)
Page 1299 of 1897

- ENGINE MECHANICALCYLINDER BLOCK
EM-91
1075 Author: Date:
2001 AVALON (RM808U)
Reference
ItemMarkmm (in.)
Cylinder block main journal bore diameter (A)º00º
º01º
º02º
º03º
º04º
º05º
º06º
º07º
º08º
º09º
º10º
º11º
º12º
º13º
º14º
º15º
º16º66.000 (2.5984)
66.001 (2.5985)
66.002 (2.5985)
66.003 (2.5985)
66.004 (2.5986)
66.005 (2.5986)
66.006 (2.5987)
66.007 (2.5987)
66.008 (2.5987)
66.009 (2.5988)
66.010 (2.5988)
66.011 (2.5989)
66.012 (2.5989)
66.013 (2.5989)
66.014 (2.5990)
66.015 (2.5990)
66.016 (2.5990)
Crankshaft main journal diameter (B)º00º
º01º
º02º
º03º
º04º
º05º
º06º
º07º
º08º
º09º
º10º
º11º
º12º61.000 (2.4016)
60.999 (2.4015)
60.998 (2.4015)
60.997 (2.4015)
60.996 (2.4014)
60.995 (2.4014)
60.994 (2.4013)
60.993 (2.4012)
60.992 (2.4012)
60.991 (2.4012)
60.990 (2.4012)
60.989 (2.4011)
60.988 (2.4011)
Standard bearing center wall thicknessº1º
º2º
º3º
º4º
º5º
º6º
º7º2.486 - 2.489 (0.0979 - 0.0980)
2.489 - 2.492 (0.0980 - 0.0981)
2.492 - 2.495 (0.0981 - 0.0982)
2.495 - 2.498 (0.0982 - 0.0983)
2.498 - 2.501 (0.0983 - 0.0985)
2.501 - 2.504 (0.0985 - 0.0986)
2.504 - 2.507 (0.0986 - 0.0987)
(l) Completely remove the Plastigage.
31. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the 4 upper main bearings and 2 upper thrust
washers from the cylinder block.
HINT:
Arrange the main bearing caps, bearings and thrust washers in
the correct order.
Page 1300 of 1897
P12404
P12405A09698
P12403
P12416
60°C
P12415
EM-92
- ENGINE MECHANICALCYLINDER BLOCK
1076 Author: Date:
2001 AVALON (RM808U)
32. 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.
33. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
HINT:
Arrange the piston rings in the correct order only.
34. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to approx. 60°C (140°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.
Page 1301 of 1897
EM0ZO-02
P12499
Z09222
P12498
- ENGINE MECHANICALCYLINDER BLOCK
EM-93
1077 Author: Date:
2001 AVALON (RM808U)
INSPECTION
1. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the
top surface of the cylinder block.
2. CLEAN CYLINDER BLOCK
Using a soft brush and solvent, thoroughly clean the cylinder
block.
NOTICE:
If the cylinder is washed at high temperatures, the cylinder
liner sticks out beyond the cylinder block, so always wash
the cylinder block at a temperature of 45°C (113°F) or less.
3. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR
FLATNESS
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head gasket for warpage.
Maximum warpage: 0.07 mm (0.0028 in.)
If warpage is greater than maximum, replace the cylinder block.
4. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
Page 1302 of 1897

Z09220
1
Thrust
Direction
Axial
Direction 1
22
A
B
C10 mm
10 mm (0.39 in.)
(0.39 in.) Front
P12500
P12497
P12507A10532
EM-94
- ENGINE MECHANICALCYLINDER BLOCK
1078 Author: Date:
2001 AVALON (RM808U)
5. 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:
87.500 - 87.512 mm (3.4449 - 3.4453 in.)
Maximum diameter: 87.52 mm (3.4457 in.)
If the diameter is greater than maximum, replace the cylinder
block.
6. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.
7. INSPECT 12 POINTED HEAD MAIN BEARING CAP
BOLTS
Using vernier calipers, measure the tension portion diameter of
the bolt.
Standard diameter:
7.500 - 7.600 mm (0.2953 - 0.2992 in.)
Minimum diameter: 7.20 mm (0.2835 in.)
If the diameter is less than minimum, replace the bolt.
8. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
Page 1303 of 1897

P12491A10534
P12505A10535
A10526
RH Piston
41.2 mm
LH Piston
P12504A10533
- ENGINE MECHANICALCYLINDER BLOCK
EM-95
1079 Author: Date:
2001 AVALON (RM808U)
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.
(c) Using solvent and a brush, thoroughly clean the piston.
NOTICE:
Do not use a wire brush.
9. INSPECT PISTON OIL CLEARANCE
(a) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 41.2 mm (1.622 in.)
from the piston head.
Piston diameter:
87.453 - 87.467 mm (3.4430 - 3.4436 in.)
(b) Measure the cylinder bore diameter in the thrust direc-
tions. (See step 5.)
(c) Subtract the piston diameter measurement from the cylin-
der bore diameter measurement.
Standard oil clearance:
0.033 - 0.059 mm (0.0013 - 0.0023 in.)
Maximum oil clearance: 0.13 mm (0.0051 in.)
If the oil clearance is greater than maximum, replace all the 6
pistons. If necessary, replace the cylinder block.
HINT:
The shape of the piston varies for the RH and LH banks. The
RH piston is marked with ºRº, the LH piston with ºLº.
10. INSPECT PISTON RING GROOVE CLEARANCE
Using a feeler gauge, measure the clearance between new pis-
ton right and the wall of the ring groove.
Ring groove clearance:
No.10.010 - 0.060 mm (0.0004 - 0.0028 in.)
No.20.020 - 0.060 mm (0.0008 - 0.0024 in.)
If the clearance is not as specified, replace the piston.
Page 1304 of 1897

P12583
105 mm
EM7639
P12506
Z04012
EM-96
- ENGINE MECHANICALCYLINDER BLOCK
1080 Author: Date:
2001 AVALON (RM808U)
11. 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 bot-
tom of the ring travel, 105 mm (4.13 in.) from the top of the
cylinder block.
(c) Using a feeler gauge, measure the end gap.
Standard end gap:
No.10.25 - 0.35 mm (0.0098 - 0.0138 in.)
No.20.35 - 0.45 mm (0.0138 - 0.0177 in.) for G2 mark
0.55 - 0.65 mm (0.0217 - 0.0256 in.) for 2T mark
Oil (Side rail)0.15 - 0.40 mm (0.0059 - 0.0157 in.)
Maximum end gap:
No.10.95 mm (0.0374 in.)
No.21.05 mm (0.0413 in.) for G2 mark
1.25 mm (0.0492 in.) for 2T mark
Oil (Side rail)1.00 mm (0.0394 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.
12. INSPECT 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.
13. INSPECT CONNECTING ROD ALIGNMENT
Using a rod aligner and feeler gauge, check the connecting rod
alignment.
Check for out-of-alignment.
Maximum out-of-alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bend is greater than maximum, replace the connecting rod as-
sembly.