Page 3713 of 5135
48106
2
3
7
9
5
1
A56226
A36648
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
14±45
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
9. REMOVE CRANKSHAFT
(a) Uniformly loosen and remove the 10 bearing cap sub±as-
sembly bolts, in several passes, in the sequence shown.
(b) Remove the bearing cap and crankshaft.
10. REMOVE CRANKSHAFT THRUST WASHER UPPER
11. REMOVE CRANKSHAFT BEARING
NOTICE:
Arrange the bearings in the correct order.
12. REMOVE CRANKSHAFT BEARING NO.2
NOTICE:
Arrange the main bearings and thrust washers in the correct order.
13. REMOVE STUD BOLT
14. INSPECT CYLINDER BLOCK FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, mea-
sure the surface contacting the cylinder head gasket for
warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
Page 3714 of 5135
A
B
10 mm
(0.39 in.)
A57506
Thrust Direction
Axial Direction Front
A56232
30.4 mm
(1.197 in.)
A36650
14±46
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
15. INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore diame-
ter at positions A and B in the thrust and axial directions.
Standard diameter:
86.000 ± 86.013 mm (3.3858 ± 3.3863 in.)
Maximum diameter: 86.013 mm (3.3863 in.)
(b) If the diameter is greater than maximum, replace the cyl-
inder block.
16. INSPECT PISTON DIAMETER
(a) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 30.3 mm (1.193 in.)
from the piston head.
Piston diameter:
85.927 ± 85.937 mm (3.3829 ± 3.3833 in.)
17. INSPECT PISTON CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.063 ± 0.086 mm (0.0025 ± 0.0034 in.)
Maximum oil clearance: 0.1 mm (0.0039 in.)
(b) If the clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder
block.
18. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between
the piston ring and the wall of the ring groove.
Ring groove clearance:
No. 1 0.020 ± 0.070 mm (0.0008 ± 0.0028 in.)
No. 2 0.020 ± 0.060 mm (0.0008 ± 0.0024 in.)
Oil ring (side rail )
w/ TWC 0.070 ± 0.150 (0.0028 ± 0.0059 in.)
w/o TWC 0.060 ± 0.140 (0.0024 ± 0.0055 in.)
Page 3715 of 5135
11 0 m m
A57507Piston Ring
EM2552
A13490
EM0227
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
14±47
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
19. INSPECT PISTON RING END GAP
(a) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 110 mm (4.33 in.) from the top of the
cylinder block.
(b) Using a feeler gauge, measure the end gap.
Standard end gap:
No. 1 0.30 ± 040 mm (0.0118 ± 0.0157 in.)
No. 2 0.47 ± 0.62 mm (0.0185 ± 0.0244 in.)
Oil (side rail) 0.10 ± 0.35 mm (0.0039 ± 0.0138 in.)
Maximum end gap:
No. 1 0.89 mm (0.0350 in.)
No. 2 1.37 mm (0.0539 in.)
Oil (side rail) 0.73 mm (0.0287 in.)
20. INSPECT PISTON PIN OIL CLEARANCE
(a) Using caliper gauge, measure the inside diameter of the
piston bushing.
Bushing inside diameter:
22.001 ± 22.010 mm (0.8662 ± 0.8665 in.)
Bushing inside diameter
Markmm (in.)
A22.001 ± 22.004 (0.8662 ± 0.8663)
B22.004 ± 22.007 (0.8663 ± 0.8664)
C22.007 ± 22.010 (0.8664 ± 0.8665)
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 ± 22.009 mm (0.8660 ± 0.8665 in.)
Piston pin diameter
MarkColormm (in.)
ABlue21.997 ± 22.000
(0.8660 ± 0.8661)
BGreen22.000 ± 22.003
(0.8661 ± 0.8663)
CColorless22.003 ± 22.006
(0.8663 ± 0.8664)
22.006 ± 22.009
(0.8664 ± 0.8665)
Page 3716 of 5135
A01185
A57508
Piston Bushing
Inside Diameter
Mark
Piston Pin
Diameter
Color
Connecting Rod
Bushing Inside Diameter Mark Front Mark
Front Mark
Z00064
14±48
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
(c) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
22.005 ± 22.014 mm (0.8663 ± 0.8667 in.)
Bushing inside diameter
Markmm (in.)
A22.005 ± 22.008 (0.8663 ± 0.8665)
B22.008 ± 22.011 (0.8665 ± 0.8666)
C22.011 ± 22.014 (0.8666 ± 0.8667)
(d) Subtract the piston pin diameter measurement from the
piton pin hole diameter measurement.
Standard oil clearance:
0.001 ± 0.007 mm (0.00004 ± 0.00028 in.)
Maximum oil clearance: 0.010 mm (0.0020 in.)
(e) If the oil clearance is greater than maximum, replace the
connecting rod. If necessary, replace the piston and pis-
ton pin as a set.
(f) Subtract the piston pin diameter measurement form the
bushing inside diameter measurement.
Standard oil clearance:
0.005 ± 0.011 mm (0.0002 ± 0.0004 in.)
Maximum oil clearance: 0.010 mm (0.0020 in.)
(g) If the oil clearance is greater than maximum, replace the
connecting rod. If necessary, replace the connecting rod
and piston pin as a set.
21. INSPECT CONNECTING ROD SUB±ASSY
(a) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Check for out±of±alignment.
Maximum out±of±alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
(b) If out±of alignment is greater than maximum, replace the
connecting rod assembly.
Page 3717 of 5135
Z00065
A01470
A13859
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
14±49
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
(1) Check for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
(c) If twist is greater than maximum, replace the connecting
rod assembly.
22. INSPECT CONNECTING ROD BOLT
(a) Using a vernier calipers, measure the tension portion di-
ameter of the bolt.
Standard diameter: 7.2 ± 7.3 mm (0.283 ± 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)
(b) If the diameter is less than minimum, replace the bolt.
23. INSPECT CRANKSHAFT
(a) Using a dial indicator and V±blocks, measure the circle
runout, ash shown in the illustration.
Maximum circle runout: 0.03 mm (0.0012 in.)
(b) Using a micrometer, measure the diameter of each main
journal.
Diameter: 54.988 ± 55.000 (2.1648 ± 2.1654 in.)
(c) Check each main journal for taper and out±of±round as
shown.
Maximum taper and out± of ±round:
0.003 mm (0.0001 in.)
Markmm (in.)
054.998 ± 55.000 (2.16528 ± 2.16535)
154.996 ± 54.998 (2.16520 ± 2.16528)
254.994 ± 54.996 (2.16512 ± 2.16520)
354.992 ± 54.994 (2.16504 ± 2.16512)
454.990 ± 54.992 (2.16496 ± 2.16504)
554.988 ± 54.990 (2.16490 ± 2.16496)
Page 3718 of 5135
ZF6928
EM6347A15065
A
B 14
13
12 AA
B B
12
A57509
6 (Ring Pin A)
5 (Ring Pin B)
Upper SideBottom Side 14±50
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
(d) Using a micrometer, measure the diameter of each crank
pin.
Diameter: 47.990 ± 48.000 mm (1.8894 ± 1.8898 in.)
(e) Check each crank pin for taper and out±of±round as
shown.
Maximum taper and out±of±round:
0.003 mm (0.0001 in.)
24. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using vernier calipers, measure the tension portion diam-
eter of the bolt.
Standard diameter: 7.5 ± 7.6 mm (0.295 ± 0.299 in.)
Minimum diameter: 7.2 mm (0.283 in.)
If the diameter is less than minimum, replace the bolt.
25. INSTALL RING PIN
(a) Using a plastic±faced hammer, tap into the ring pin.
Standard protrusion:
Ring pin A 6 mm (0.236 in.)
Ring pin B 5 mm (0.197 in.)
Page 3719 of 5135
A53029
A13854
A13868
A13987
1
2 3
45
6 7
89
10 7
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
14±51
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
26. INSPECT CRANKSHAFT OIL CLEARANCE
NOTICE:
Clean the backside of the bearing and the bearing
surface of the bearing cap and let not stick the oils
and fats.
The bearing cap bolts are tightened in 2 progressive
steps.
(a) Clean each main journal and bearing.
(b) Install the upper bearing with an oil groove on cylinder
block.
(c) Install the lower bearing on the bearing cap sub assem-
bly.
(d) Place the crankshaft on the cylinder block.
(e) Lay a strip of plastigage across each journal.
(f) Examine the front marks and install the bearing caps on
the cylinder block.
(g) Apply a light coat of engine oil on the threads and under
the bearing cap bolts.
(h) Tighten the bolts in several passes, in the sequence
shown, by the specified torque.
Torque: 20 Nm (205 kgfcm, 15 ftlbf)
(i) Retighten the bolts in several passes, in the sequence
shown, by the specified torque.
Torque: 40 Nm (410 kgfcm, 30 ftlbf)
Page 3720 of 5135
90
A57501
Engine FrontPaint
Mark
A13855
A13856
14±52
± ENGINE MECHANICALCYLINDER BLOCK (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
(j) Mark the front of the bearing cap bolts with paint.
(k) Retighten the bearing cap bolts by 90 in the numerical
order shown.
(l) Check that the painted mark is now at a 90 angle to the
front.
NOTICE:
Do not turn the crankshaft.
(m) Remove the bearing cap.
(n) Measure the plastigage at its widest point.
Standard oil clearance:
0.017 ± 0.040 mm (0.0007 ± 0.0016 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
NOTICE:
Completely remove the plastigage.
(o) If using a standard bearing, replace it 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 crank-
shaft, then selecting the bearing with the same number as
the total. There are 4 sizes of standard bearings, marked
º1º, º2º, º3º and º4º accordingly.
Cylinder block
(A)
+
Crankshaft (B)
0 ± 23 ± 56 ± 89 ± 11
Use bearingº1ºº2ºº3ºº4º
HINT:
EXAMPLE
Cylinder block º4º (A) + Crankshaft º3º (B) =
Total number 7 (Use bearing º3º)