Part 1

CYLINDER BLOCK ASSEMBLY (2GR-FE)





COMPONENTS

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: 0.15 to 0.40 mm (0.0059 to 0.0157 inch)
Maximum thrust clearance: 0.50 mm (0.020 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE
a. Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.

HINT: The matchmarks on the connecting rods and caps are provided to ensure correct reassembly.





b. Using SST, remove the 2 connecting rod cap bolts.
SST 09011-38121





c. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

HINT: Keep the lower bearing inserted to the connecting rod cap.

d. Clean the crank pin and bearing.
e. Check the crank pin and bearing for pits and scratches.





f. Lay a strip of Plastigage on the crank pin.





g. Check that the front mark of the connecting rod cap is facing forward.





h. Using SST, install the connecting rod cap. (see step 34)
SST 09011-38121

NOTICE: Do not turn the crankshaft.

i. Remove the 2 bolts and connecting rod cap (see steps (b) and (c) above).





j. Measure the Plastigage at its widest point.
Standard oil clearance: 0.045 to 0.067 mm (0.0018 to 0.0026 inch)
Maximum oil clearance: 0.070 mm (0.0028 inch)
If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, replace the crankshaft.

HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, 3 and 4 mark on its surface.

Reference:




Connecting rod diameter




Standard bearing center wall thickness
Crankshaft pin diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 inch)

k. Completely remove the Plastigage.





3. REMOVE PISTON SUB-ASSEMBLY 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

HINT: Arrange the removed parts in the correct order.





5. 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: 0.04 to 0.24 mm (0.0016 to 0.0094 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.
Thrust washer thickness: 2.43 to 2.48 mm (0.0957 to 0.0976 inch)
6. REMOVE CRANKSHAFT





a. Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in several steps and in the sequence shown in the illustration.





b. Uniformly loosen the 16 bearing cap bolts in several steps and in the sequence shown in the illustration.





c. Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and lower bearings.

NOTICE:
- Pull up the main bearing caps little by little to the right and the left in turns.
- Be careful not to damage the joint surface of the cylinder block and the main bearing caps.

7. REMOVE CRANKSHAFT BEARING

HINT: Arrange the removed parts in the correct order.





8. REMOVE CRANKSHAFT THRUST WASHER SET
a. Remove the upper bearings and upper thrust washers from the cylinder block.





9. REMOVE PISTON RING SET
a. Using a piston ring expander, remove the 2 compression rings.
b. Using a piston ring expander, remove the 2 side rails.
c. Remove the oil ring expander by hand.

HINT: Arrange the piston rings in the correct order.

10. REMOVE PISTON SUB-ASSEMBLY WITH PIN





a. Check the fitting condition between the piston and piston pin.
1. 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.
b. Disconnect the connecting rod from the piston.





1. Using a screwdriver, pry off the snap rings from the piston.





2. Gradually heat the piston to approximately 80°C (176°F),





3. Using a brass bar and plastic hammer, 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.





c. Using a gasket scraper, remove the carbon from the piston top.





d. Using a groove cleaning tool or broken ring, clean the piston ring grooves.





e. Using solvent and a brush, thoroughly clean the piston.

NOTICE: Do not use a wire brush.





11. REMOVE SUB-ASSEMBLY OIL NOZZLE NO.1
a. Using a 5 mm hexagon wrench, remove the 3 oil nozzles.
b. Check the oil nozzles for damage or clogging.
If necessary, replace the oil nozzle.

12. INSPECT CYLINDER BLOCK FOR WARPAGE





a. Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.
Maximum warpage: 0.07 mm (0.0028 inch)
If the warpage is greater than the maximum, replace the cylinder block.





b. Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 6 cylinders. If necessary, replace the cylinder block.





13. INSPECT CYLINDER BORE
a. Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.
Standard diameter: 94.000 to 94.012 mm (3.7008 to 3.7013 inch)
Maximum diameter: 94.200 mm (3.7087 inch)
If the diameter is greater than the maximum, replace the cylinder block.





14. INSPECT PISTON SUB-ASSEMBLY WITH PIN
a. Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston end is as specified.
Distance: 9.8 mm (0.3858 inch)
Standard diameter: 93.960 to 93.980 mm (3.6992 to 3.7000 inch)
Maximum diameter: 93.830 mm (3.6941 inch)
15. INSPECT PISTON OIL CLEARANCE
a. Measure the cylinder bore diameter in the thrust direction (see step 13).
b. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.02 to 0.052 mm (0.0008 to 0.0020 inch)
Maximum oil clearance: 0.06 mm (0.0024 inch)
If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.





16. INSPECT RING GROOVE CLEARANCE
a. Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.





Ring groove clearance
If the clearance is not as specified, replace the piston.





17. 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 bottom of the ring travel, 110 mm (4.33 inch) from the top of the cylinder block.





c. Using a feeler gauge, measure the end gap.




Standard end gap




Maximum end gap
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 piston ring, replace the cylinder block.





18. INSPECT PISTON PIN OIL CLEARANCE
a. Using a caliper gauge, measure the inside diameter of the piston pin hole.




Piston pin hole inside diameter





b. Using a micrometer, measure the piston pin diameter.




Piston pin diameter





c. Subtract the piston pin diameter measurement from the piston pin hole diameter measurement.
Standard oil clearance: 0.001 to 0.007 mm (0.00002 to 0.0003 inch)
Maximum oil clearance: 0.015 mm (0.0006 inch)

HINT: If the oil clearance is greater than the maximum, replace the piston and piston pin as a set.

d. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.




Bushing inside diameter





e. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 inch)
Maximum oil clearance: 0.03 mm (0.0012 inch)

HINT: If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin as a set.

19. INSPECT CONNECTING ROD





a. Using a rod aligner and feeler gauge, check the connecting rod alignment.
1. Check for out-of-alignment.
Maximum out-of alignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If out-of-alignment is greater than the maximum, replace the connecting rod assembly.





2. Check for twist.
Maximum twist: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)
If twist is greater than the maximum, replace the connecting rod assembly.





20. REMOVE CONNECTING ROD SMALL END BUSH
a. Using SST and a press, press out the bush.
SST 09222-30010





21. INSPECT CONNECTING ROD BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 inch)
Minimum diameter: 7.0 mm (0.276 inch) If the diameter is less than the minimum, replace the bolt.





22. 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 inch)
If the circle runout is greater than the maximum, replace the crankshaft.





b. Inspect the main journals.
1. Using a micrometer, measure the diameter of each main journal.
Standard journal diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 inch)
If the diameter is not as specified, check the oil clearance (see step 23). If necessary, replace the crankshaft.
2. Check each main journal for taper and out-of-round as shown in the illustration.
Maximum taper and out-of-round: 0.02 mm (0.0008 inch)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.





c. Inspect the crank pin.
1. Using a micrometer, measure the diameter of each crank pin.
Diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 inch)
If the diameter is not as specified, check the oil clearance (see step 2). If necessary, replace the crankshaft.
2. Check each crank pin for taper and out-of-round as shown in the illustration.
Maximum taper and out-of-round: 0.02 mm (0.0008 inch)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.