Page 3705 of 5135
D25218
SST
D25219
SST
D25216
SST
D25217
SST
D25215
90 ± 100 C (194 ± 230 F) 40±104
± AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
13. INSTALL FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing rear inner race to the differential
case.
SST 09608±06041
(b) Using SST and a hammer, install the case washer and
front differential case tapered roller bearing rear outer
race to the transaxle case.
SST 09950±60020 (09951±00710), 09950±70010
(09951±07100)
14. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing front inner race to the differential
case.
SST 09608±06041
(b) Using SST and a hammer, install the front differential
case tapered roller bearing front outer race to the trans-
axle housing.
SST 09950±60020 (09951±00680), 09950±70010
(09951±07100), 09950±60010 (09951±00340)
15. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and hear, hear the front differential ring gear
to 90 ± 110 C (194.0 ± 230.0 F).
(b) Clean the contact surface of the front differential case.
Page 3706 of 5135
C83132
Match±marks
C83133
C83139
C50259
C
C
C
CA
AA B
BB
C83572
SST
± AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U241E)
40±105
U241E A/T REPAIR MANUAL (RM840U)
(c) Set the match±marks, install the front differential ring gear
case quickly.
(d) Tighten the 10 bolts.
Torque: 95 Nm (969 kgfcm, 70 ftlbf)
16. INSPECT TAPERED POLLER BEARING PRELOAD
(a) Install the differential assy to the transaxle case.
(b) Install the transaxle housing to the transaxle case.
(c) Install the 16 bolts.
Torque:
Bolt A, B: 29.4 Nm (300 kgfcm, 21.7 ftlbf)
Bolt C: 22.1 Nm (225 kgfcm, 16.3 ftlbf)
BoltBolt length (mm)
A, B42
C50
(d) Using SST, turn the differential assy.
SST 09564±32011
Page 3707 of 5135
C83572
SST
D09182
C83139
40±106
± AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
(e) Using SST and torque wrench, measure the preload of
the differential assy.
SST 09564±32011
Preload
New bearing:
0.20 ± 0.69 Nm (2.0 ± 7.0 kgfcm, 1.8 ± 6.1 in.lbf)
Used bearing:
0.10 ± 0.35 Nm (1.0 ± 3.6 kgfcm, 0.9 ± 3.1 in.lbf)
Adjusting shim thickness: mm (in.)
MarkThickness
01.90 (0.074)
11.95 (0.077)
22.00 (0.079)
32.05 (0.081)
42.10 (0.083)
52.15 (0.085)
62.20 (0.087)
72.25 (0.089)
82.30 (0.091)
92.35 (0.093)
A2.40 (0.094)
B2.45 (0.096)
C2.50 (0.098)
D2.55 (0.100)
E2.60 (0.102)
F2.65 (0.104)
G2.70 (0.106)
H2.75 (0.108)
J2.80 (0.110)
(f) Remove the 16 bolts.
(g) Using a practice hammer, remove the transaxle housing.
(h) Remove the differential assy.
Page 3708 of 5135
D25606
SST
D25605
SST
± AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U241E)
40±107
U241E A/T REPAIR MANUAL (RM840U)
17. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Using SST, drive into a new oil seal.
SST 09350±32014 (09351±32150), 09950±70010
(09951±07150)
(b) Coat the rip of oil seal with a little MP grease.
18. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, drive into a new oil seal.
SST 09350±32014 (09351±32150), 09950±70010
(09951±07150)
(b) Coat the rip of the oil seal with a little MP grease.
Page 3709 of 5135
020JR±01
02±6
± PREPARATIONSTARTING & CHARGING
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
STARTING & CHARGING
PREPARATION
SST
09820±63010Alternator Pulley Set Nut Wrench
SetGENERATOR ASSY(1AZ±FE)
(09820±06010)Alternator Rotor Shaft WrenchGENERATOR ASSY(1AZ±FE)
(09820±06020)Alternator Pulley Set Nut 22 mm
WrenchGENERATOR ASSY(1AZ±FE)
Recomended Tools
09082±00040TOYOTA Electrical TesterSTARTER ASSY(1.3KW)(1AZ±FE)
Equipment
V±block
Dial indicator
Ohmmeter
Torque wrench
Vernier calipers
Dial indicator with magnetic base
Press
Page 3710 of 5135
140DW±01
A13845
A13846
A13848
A13874
14±42
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
CYLINDER BLOCK (1AZ±FE)
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:
0.160 ± 0.362 mm (0.0063 ± 0.0143 in.)
Maximum thrust clearance: 0.362 mm (0.0143 in.)
(b) If the thrust clearance is greater than maximum, replace
the connecting rod assembly(s). If necessary, replace the
crankshaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE
HINT:
The connecting rod cap bolts are tightened in 2 progressive
steps.
(a) Check the matchmarks on the connecting rod and cap are
aligned to ensure correct reassembly.
HINT:
The matchmarks on the connecting rods and caps are for en-
suring correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Clean the crank pin and bearing.
(d) Check the crank pin and bearing for pitting and scratches.
(e) Lay a strip of plastigage on the crank pin.
(f) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
(g) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(h) Tighten the bolts in several passes by the specified
torque.
Torque: 25 Nm (250 kgfcm, 18 ftlbf)
Page 3711 of 5135
90
A57501
Engine FrontPaint
Mark
A13850
A57505
Mark
1, 2 or 3Mark
1, 2 or 3
A13469
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
14±43
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
(i) Mark the front of the connecting rod 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 bear-
ing.
(l) Measure the plastigage at its widest point.
Standard oil clearance:
0.024 ± 0.048 mm (0.0009 ± 0.0019 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
NOTICE:
Completely remove the plastigage.
(m) If replacing a bearing, replace it with one having the same
number as marked on the connecting rod. There are 3
sizes of standard bearings, marked º1º, º2º and º3º ac-
cordingly.
HINT:
Standard bearing center wall thickness.
Mark 11.485 ± 1.488 mm (0.0585 ± 0.0586 in.)
Mark 21.488 ± 1.491 mm (0.0586 ± 0.0587 in.)
Mark 31.491 ± 1.494 mm (0.0587 ± 0.0588 in.)
3. REMOVE PISTON SUB±ASSY W/CONNECTING ROD
(a) Using a ridge reamer, remove all the 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.
Arrange the piston and connecting rod assemblies in the
correct order.
4. REMOVE CONNECTING ROD BEARING
Page 3712 of 5135
A36647
A13478
A01178
A01179
A13851
14±44
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
5. REMOVE PISTON RING SET
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
6. REMOVE PISTON PIN HOLE SNAP RING
(a) Using a small screwdriver, pry out the 2 snap rings.
7. REMOVE PISTON
(a) Gradually heat the piston to 80 ± 90 C (176 ± 194 F).
(b) 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.
8. 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:
0.040 ± 0.240 mm (0.0016 ± 0.0094 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
(b) If the thrust clearance is greater than maximum, replace
the thrust washers as a set.
Thrust washer thickness:
1.930 ± 1.980 mm (0.0760 ± 0.0780 in.)