Page 4785 of 5135
A36648
Thrust Direction
Axial Direction
Front
A88899
10 mm A
B
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
14−61
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
15. CLEAN CYLINDER BLOCK
NOTICE:
If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block.
Always wash the cylinder block at a temperature of 45_C(113_F) or less.
16. 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.)
If the warpage is greater than the maximum, replace the cylin-
der block.
17. 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:
88.500 to 88.513 mm (3.4843 to 3.4848 in.)
Maximum diameter: 88.633 (3.4895 in.)
If the diameter is greater than the maximum, replace the cylin-
der block.
Page 4786 of 5135

A92496
30.3 mm
A36650
Piston Ring11 0 m mA53017
EM2552
14−62
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
18. 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:
88.439 to 88.449 mm (3.4818 to 3.4822 in.)
19. INSPECT PISTON CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.051 to 0.074 mm (0.0020 to 0.0029 in.)
Maximum oil clearance: 0.1 mm (0.0039 in.)
If the clearance is greater than the maximum, replace all the 4 pistons.
If necessary, replace the cylinder block.
20. 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:
ItemSpecified Condition
No. 10.030 to 0.080 mm (0.0011 to 0.0031 in.)
No. 20.020 to 0.060 mm (0.0008 to 0.0024 in.)
Oil (side rail)0.020 to 0.070 mm (0.0008 to 0.0028 in.)
If the clearance is not as specified, replace the piston.
21. 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:
ItemSpecified Condition
No. 10.22 to 0.32 mm (0.0087 to 0.0126 in.)
No. 20.50 to 0.60 mm (0.0197 to 0.0236 in.)
Oil (side rail)0.10 to 0.35 mm (0.0039 to 0.0138 in.)
Page 4787 of 5135

A13490
EM0227
A01185
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
14−63
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
Maximum end gap:
ItemSpecified Condition
No. 10.89 mm (0.0350 in.)
No. 21.35 mm (0.0531 in.)
Oil (side rail)0.73 mm (0.0287 in.)
If the end gap is greater than the maximum, replace the piston
ring.
If the end gap is greater than the maximum even with a new pis-
ton ring, replace the cylinder block.
22. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the pin hole bush diame-
ter of the piston.
Pin hole diameter (Reference):
MarkSpecified Condition
A22.001 to 22.004 mm (0.8662 to 0.8663 in.)
B22.005 to 22.007 mm (0.8663 to 0.8664 in.)
C22.008 to 22.010 mm (0.8665 to 0.8665 in.)
If the diameter is not as specified, check the oil clearance.
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter (Reference):
MarkSpecified Condition
A21.997 to 22.000 mm (0.8660 to 0.8661 in.)
B22.001 to 22.003 mm (0.8662 to 0.8663 in.)
C22.004 to 22.006 mm (0.8663 to 0.8664 in.)
D22.007 to 22.009 mm (0.8664 to 0.8665 in.)
(c) Using a caliper gauge, measure the inside diameter of the
connecting rod bush.
Bush inside diameter:
MarkSpecified Condition
A22.005 to 22.008 mm (0.8663 to 0.8665 in.)
B22.008 to 22.011 mm (0.8665 to 0.8666 in.)
C22.011 to 22.014 mm (0.8666 to 0.8667 in.)
(d) Subtract the piston pin diameter measurement from the
piton pin hole diameter measurement.
Standard oil clearance:
0.001 to 0.007 mm (0.00004 to 0.00028 in.)
Maximum oil clearance: 0.010 mm (0.0020 in.)
Page 4788 of 5135

Piston Bushing
Inside Diameter
Mark
Connecting Rod
Bushing Inside Diameter MarkFront Mark
Front Mark
A62247
Z00064
Z00065
A01470
14−64
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
If the oil clearance is greater than the maximum, replace the
connecting rod. If necessary, replace the piston and piston pin
as a set.
(e) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
Specified oil clearance:
0.005 to 0.100 mm (0.0002 to 0.0020 in.)
If the oil clearance is greater than the maximum, replace the
connecting rod. If necessary, replace the connecting rod and
piston pin as a set.
23. 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.)
If the out−of−alignment is greater than the maximum, replace
the connecting rod assembly.
(2) Check for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum, replace the connecting
rod assembly.
24. INSPECT CONNECTING ROD BOLT
(a) Using a vernier caliper, measure the tension portion diam-
eter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)
If the diameter is less than the minimum, replace the bolt.
Page 4789 of 5135

A13491
A92497
No. 1
No. 5 No. 4No. 3 No. 2
ZF6928
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
14−65
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
25. INSPECT CRANKSHAFT
(a) Using a dial indicator and V−blocks, measure the circle
runout, as shown in the illustration.
Maximum circle runout: 0.03 mm (0.0012 in.)
If the circle runout is greater than the maximum, replace the
crankshaft.
(b) Using a micrometer, measure the diameter of each main
journal.
Diameter: 54.988 to 55.000 (2.1648 to 2.06535 in.)
If the diameter is not as specified, check the oil clearance (see
step 9). If necessary, replace the crankshaft.
(c) Check each main journal for taper and out−of−round as
shown in the illustration.
Maximum taper and out−of−round:
0.003 mm (0.0001 in.)
If the taper and out−of−round is greater than the maximum, re-
place the crankshaft.
Diameter (Reference):
MarkSpecified Condition
054.999 to 55.000 mm (2.16531 to 2.16535 in.)
154.997 to 54.998 mm (2.16523 to 2.16528 in.)
254.995 to 54.996 mm (2.16515 to 2.16520 in.)
354.993 to 54.994 mm (2.16507 to 2.16512 in.)
454.991 to 54.992 mm (2.16500 to 2.16504 in.)
554.988 to 54.990 mm (2.16490 to 2.16496 in.)
(d) Using a micrometer, measure the diameter of each crank
pin.
Diameter: 47.990 to 48.000 mm (1.8894 to 1.8898 in.)
If the diameter is not as specified, check the oil clearance (see
step 2). If necessary, replace the crankshaft.
(e) Check each crank pin for taper and out−of−round as
shown in the illustration.
Maximum taper and out−of−round:
0.003 mm (0.0001 in.)
If the taper and out−of−round is greater than the maximum, re-
place the crankshaft.
Page 4790 of 5135
EM6347A15065
A92498
14 mm
(0.551 in.)
6 mm (0.236 in.)
for Ring Pin A
5 mm (0.197 in.)
for Ring Pin B
12 mm
(0.472 in.)12 mm
(0.472 in.) 13 mm
(0.512 in.)A
AB
B
Upper SideBottom Side 14−66
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
26. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using a vernier caliper, measure the tension portion diam-
eter of the bolt.
Standard diameter: 7.5 to 7.6 mm (0.295 to 0.299 in.)
Minimum diameter: 7.2 mm (0.283 in.)
If the diameter is less than the minimum, replace the bolt.
27. INSTALL RING PIN
(a) Using a plastic−faced hammer, tap into the ring pin.
Page 4791 of 5135
A62239
Standard depth:
Engine front
1.7 to 2.7 mm (0.067 to 0.106 in.)
Engine rear
2.2 to 3.2 mm (0.087 to 0.126 in.)
A92499
18 mm
(0.71 in.)
9mm
(0.35 in.) 31.5 mm
(1.24 in.)
84 mm
(3.31 in.)
20 mm
(0.79 in.)16 mm
(0.63 in.)14 mm
(0.55 in.)
9mm
(0.35 in.) 27.5 mm
(1.08 in.)
A (M16)B (M10)C (M6) A
BAC
Front SideExhaust Side
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
14−67
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
28. INSTALL TIGHT PLUG
(a) Apply adhesive around the tight plugs.
Adhesive: Part No. 08833−00070, THREE BOND 1324
or equivalent
(b) Using SST, install new tight plugs as shown in the illustra-
tion.
SST 09950−60010 (09951−00200), 09950−70010
(09951−07100)
29. INSTALL STUD BOLT
(a) Install the stud bolts as shown in the illustration.
Torque:
5.0 Nm (51 kgfcm, 44 in.lbf) for stud bolt A
10 Nm (102 kgfcm, 7 ftlbf) for stud bolt B
5.0 Nm (51 kgfcm, 44 in.lbf) for stud bolt C
Page 4792 of 5135
A92500
8mm
(0.31 in.)
15 mm
(0.59 in.)10 mm
(0.39 in.)
22 mm
(0.87 in.)7.5 mm (0.30 in.)
for Pin A
12 mm (0.47 in.)
for Pin B
Back SideBottom SideFront Side
ABAA
A
A B
B
P12418A32958
Front Mark
Front Mark
A13497
14−68
− ENGINE MECHANICALCYLINDER BLOCK ASSY (2AZ−FSE)
2AZ−FSE ENGINE REPAIR MANUAL (RM1083E)
30. INSTALL STRAIGHT PIN
(a) Using a plastic−faced hammer, tap into the straight pin.
31. INSTALL PISTON
(a) Using a small screwdriver, install a new snap ring at one
end of the piston pin hole.
(b) Gradually heat the piston to approximately 80 to 90_C
(176 to 194_F).
(c) Align the front marks of the piston and connecting rod,
and push in the piston with your thumb.
(d) Using a small screwdriver, install a new snap ring on the
other end of the piston pin hole.