ENGINE REPAIR MANUAL.pdf

16–1

COOLING

–

WATER PUMP ASSY (1ZZ–FE/3ZZ–FE)

INSPECTION

160AO–01

INSPECT WATER PUMP ASSY

(a)

Visually check the drain hole for coolant leakage.

Hole

B10233

1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL

(RM923E)

14–38

ENGINE MECHANICAL

–

CYLINDER BLOCK (1ZZ–FE/3ZZ–FE)

COMPONENTS

140KO–01

Compression Ring No.1

Compression Ring No.2

Oil Ring (Side Rail)

Oil Ring (Expander)

Snap Ring

Piston

Snap Ring

Piston Pin

Bush

Connecting Rod

Connecting Rod Bearing

5.0 (51, 44 in.

lbf)

Ring Pin

Straight Pin

Cylinder Block Sub–assy

11 (112, 8)

Ring Pin

5.0 (51, 44 in.

lbf)

Crankshaft Bearing

Crankshaft Thrust Washer Upper

Straight Pin

Crankshaft

Thrust Washer Upper

Key

Crankshaft

Crankshaft Bearing

Connecting Rod Bearing

Connecting Rod Bearing Cap

See page 14–39

1st 20 (204, 15)

2nd Turn 90

Crankshaft Bearing Cap Sub–assy

Straight Pin

Ring Pin

19 (194, 14)

See page 14–39

5.0 (51, 44 in.

lbf)

1st 44 (449, 33)

2nd Turn 90

N·m (kgf·cm, ft·lbf) : Specified torque

Non–reusable part

5.0 (51, 44 in.

lbf)

A62767

1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL

(RM923E)

14–39

ENGINE MECHANICAL

–

CYLINDER BLOCK (1ZZ–FE/3ZZ–FE)

140KP–01

OVERHAUL

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 – 0.342 mm (0.063 – 0.0135 in.)

Maximum thrust clearance: 0.342 mm (0.0135 in.)

A01155

2. INSPECT CONNECTING ROD BEARING OIL

CLEARANCE

NOTICE:

Do not turn the crankshaft.

(a)

Using marking paint, write the matched cylinder number

on each connecting rod and cap.

HINT:

The match marks on the connecting rods and caps are for en-

suring correct reassembly.

(b)

A01156

Using SST, remove the 2 connecting rod cap bolts.

SST

09205–16010

(c)

Clean the crank pin and bearing.

(d)

Check the crank pin and bearing for pitting and scratches.

(e)

Lay a strip of Plastigage across the crank pin.

Plastigage

A01159

(f)

Check that the protrusion of the connecting rod cap is fac-

ing in the correct direction.

Front

A62797

1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL

(RM923E)

14–40

ENGINE MECHANICAL

–

CYLINDER BLOCK (1ZZ–FE/3ZZ–FE)

(g)

Apply a light coat of engine oil on the threads and under

the heads of the connecting rod cap bolts.

(h)

Using SST, tighten the bolts in several passes by the spe-

cified torque.

SST 09205–16010

Torque: 20 N m (204 kgf cm, 15 ft lbf)

A01163

(i)

Mark the front of the connecting cap bolts with paint.

(j)

Retighten the cap bolts by 90

as shown in the illustration.

Paint Mark

(k)

Check that the crankshaft turns smoothly.

Front

(l)

Remove the 2 bolts, connecting rod cap and lower bear-

ing.

A62798

(m) Measure the Plastigage at its widest point.

Standard oil clearance:

0.028 – 0.060 mm (0.0011 – 0.0024 in.)

Maximum oil clearance: 0.080 mm (0.0031 in.)

NOTICE:

Remove the Plastigage completely after the measurement.

A01160

(n)

If replacing a bearing, select a new one having the same

number as marked on the connecting rod. There are 3

sizes of standard bearings, marked ”1”, ”2” and ”3” ac-

cordingly.

Reference:

Standard bearing center wall thickness

Mark

1, 2 or 3

mm (in.)

1.486 – 1.490 (0.0585 – 0.0587)

1.490 – 1.494 (0.0587 – 0.0588)

A62799

1.494 – 1.498 (0.0588 – 0.0590)

REMOVE PISTON SUB–ASSY W/CONNECTING ROD

(a)

Using a ride 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.

A01166

1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL

(RM923E)

14–41

ENGINE MECHANICAL

–

CYLINDER BLOCK (1ZZ–FE/3ZZ–FE)

REMOVE CONNECTING ROD BEARING

(a)

Remove the connecting rod bearing from the connecting rod and crankshaft.

REMOVE PISTON RING SET

HINT:

Take care not to misplace the piston rings on both the match

with the piston and the direction of the rings.

(a)

Using a piston ring expander, remove the 2 compression

rings.

(b)

Remove the 2 side rails and oil ring by hand.

A01175

REMOVE PISTON PIN HOLE SNAP RING

(a)

Using a small screwdriver, pry out the 2 snap rings.

A01192

REMOVE W/PIN PISTON SUB–ASSY

(a)

Gradually heat the piston to 80 – 90

C (176 – 194

F).

(b)

Using a plastic 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 piston, pins, ring, connecting rod and bear-

ings in the correct order.

A01179

REMOVE CONNECTING ROD SMALL END BUSH

SST

(a)

Using SST and a press, press out the bushing.

SST

09222–30010

A62800

1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL

(RM923E)

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