Overhaul: 1. Inspect Connecting Rod Thrust Clearance

14−61
ENGINE MECHANICAL − CYLINDER BLOCK ASSY (2TR−FE)

1421T−02
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:
0.150 to 0.350 mm (0.0059 to 0.0138 in.)
Maximum thrust clearance: 0.40 mm (0.016 in.)
If the thrust clearance is greater than the maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
G37344 shaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check that the matchmarks on the connecting rod and
cap are aligned to ensure the correct reassembly.
HINT:
The matchmarks on the connecting rods and caps are for en-
suring the correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(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 pitting and scratches.
G37345
Plastigage
(f) Lay a strip of Plastigage on the crank pin.
G37346
(g) Check that the front mark of the connecting rod cap is fac-
Front Mark
ing forward.
G37347
2TR−FE ENGINE REPAIR MANUAL (RM1152E)

14−62
(h) Install the connecting rod cap. (see step 51)

NOTICE:
Do not turn the crankshaft.
(i) Remove the 2 bolts and connecting rod cap (see steps (b)
and (c) above).
G37348
(j) Measure the Plastigage at its widest point.

Plastigage
Standard oil clearance:
0.024 to 0.049 mm (0.0009 to 0.0019 in.)
Maximum oil clearance: 0.066 mm (0.0026 in.)
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 and 3 mark on its sur-
face.
Reference:
Crankshaft pin diameter:
Mark Thickness
4 52.989 to 53.002 mm (2.0862 to 2.0867 in.)
5 52.989 to 53.002 mm (2.0862 to 2.0867 in.)
6 52.989 to 53.002 mm (2.0862 to 2.0867 in.)
Standard bearing center wall thickness:
G37350 4, 5 or 6 Mark
G37351 G39628 Mark Thickness
4 1.484 to 1.487 mm (0.0584 to 0.0585 in.)
5 1.488 to 1.490 mm (0.0586 to 0.0587 in.)
6 1.491 to 1.493 mm (0.0587 to 0.0588 in.)
(k) Completely remove the Plastigage.
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
Ridge Reamer
bearing through the top of the cylinder block.
HINT:
S Keep the bearing, connecting rod and cap together.
S Arrange the piston and connecting rod assemblies in the
G35191 correct order.

14−63
4. REMOVE CONNECTING ROD BEARING

HINT:
Arrange the removed parts in the correct order.
5. INSPECT CRANKSHAFT THRUST CLEARANCE

prying the crankshaft back and forth with a screwdriver.
0.020 to 0.220 mm (0.0008 to 0.0087 in.)
thrust washers as a set. If necessary, replace the crankshaft.
G37352 Thrust washer thickness:
2.440 to 2.490 mm (0.0961 to 0.0980 in.)
6. REMOVE CRANKSHAFT
4 8 10 6 2 (a) Uniformly loosen the 10 bearing cap bolts, in several
steps, in the sequence shown in the illustration.
HINT:
S Keep the lower bearings and crankshaft bearing caps to-
gether.
3 7 9 5 1 S Arrange the thrust washers in the correct order.
(b) Lift out the crankshaft.
G37353
(c) Remove the upper bearings and upper thrust washers

from the cylinder block.
HINT:
Arrange the main bearing caps, bearings and thrust washers in
the correct order.
G37374
7. REMOVE CRANKSHAFT BEARING

HINT:
Arrange the removed parts in the correct order.

14−64
8. REMOVE PISTON RING SET

(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Using a piston ring expander, remove the oil ring rail.
(c) Remove the oil ring expander by hand.
HINT:
Arrange the piston rings in the correct order.
G37354
9. REMOVE CYLINDER BLOCK WATER DRAIN COCK

SUB−ASSY
(a) Remove the water drain cock sub−assy from the cylinder
block.
(b) Remove the water drain cock plug from the water drain
cock sub−assy.
G37307
10. REMOVE W/PIN PISTON SUB−ASSY

(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.
G35197
(b) Disconnect the connecting rod from the piston.

(1) Using a screwdriver, pry off the snap rings from the
piston.
Service Hole
G37386
(2) Gradually heat the piston to approximately 80 to

90_C (176 to 194_F).
80 to 90˚C
A01178

14−65
(3) Using a brass bar and plastic−faced hammer, lightly

tap out the piston pin and remove the connecting
rod.
HINT:
S The piston and pin are a matched set.
S Arrange the pistons, pins, rings, connecting rods and
bearings in the correct order.
G36556
11. CLEAN W/PIN PISTON SUB−ASSY

(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
G35192
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.
G35193
(c) Using solvent and a brush, thoroughly clean the piston.

NOTICE:
Do not use a wire brush.
G35194
12. REMOVE SUB−ASSY OIL NOZZLE NO.1

(a) Using a 5 mm hexagon wrench, remove the oil nozzles.
G37357

14−66
13. INSPECT SUB−ASSY OIL NOZZLE NO.1

(a) Check the oil nozzles for damage or clogging.
If necessary, replace the oil nozzle.
14. INSPECT BALANCE SHAFT THRUST CLEARANCE

moving the balanceshaft back and forth.
0.07 to 0.13 mm (0.0027 to 0.0051 in.)
balanceshaft thrust washer. If necessary, replace the balance-
G37388 shaft.
15. REMOVE NO.1 BALANCESHAFT

(a) Remove the bolt.
G37389
(b) Remove the balanceshaft from the cylinder block.

NOTICE:
When removing the balanceshaft, make sure to support the
balanceshaft with both hands and avoid scratching the ba-
lanceshaft bearing on the cylinder block side.
G37390
16. REMOVE BALANCESHAFT DRIVEN GEAR NO.1

L2 L3
(a) Mount the head portion of the balanceshaft in a vise.
NOTICE:
Be careful not to damage the balanceshaft.
(b) Remove the bolt.
L1
L4 (c) Remove the balanceshaft driven gear No.1 (L 1), sliding
key (L 2), balanceshaft thrust washer No.1 (L 3) and ba-
lanceshaft thrust spacer (L 4).
G37391

14−67
17. REMOVE NO.2 BALANCESHAFT

(a) Remove the 2 bolts.
G37392
(b) Remove the balanceshaft from the cylinder block.

NOTICE:
When removing the balanceshaft, make sure to support the
G37393
18. REMOVE BALANCESHAFT DRIVEN GEAR NO.2

L2
NOTICE:
(b) Remove the bolt.
L1
(c) Remove the balanceshaft driven gear No.2 (L 1) and ba-
lanceshaft thrust washer No.2 (L 2).
G37394
19. INSPECT CYLINDER BLOCK FOR FLATNESS

(a) Using a precision straight edge and feeler gauge, mea-
sure the warpage of the contact surface of the cylinder
head gasket.
Maximum warpage: 0.05 mm (0.0020 in.)
If the warpage is greater than the maximum, replace the cylin-
der block.
G37356

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(b) Visually check the cylinder for vertical scratches.

If deep scratches are present, rebore all the 4 cylinders. If nec-
essary, replace the cylinder block.
G35190
20. INSPECT CYLINDER BORE

(a) Using a cylinder gauge, measure the cylinder bore diame-
ter at positions A in the thrust and axial directions.
Standard diameter:
94.990 to 95.003 mm (3.7398 to 3.7403 in.)
Maximum difference diameter: 0.2 mm (0.008 in.)
If the diameter is greater than the maximum, rebore all the 4 cyl-
inders. If necessary, replace the cylinder block.
Thrust Direction
Front
Axial Direction
A
70 mm
(2.76 in.) G37358
(b) Inspect the cylinder ridge.

If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.
Ridge Reamer
G35191
21. CLEAN CYLINDER BLOCK

(a) Using a gasket scraper, remove all the gasket material
from the top surface of the cylinder block.
(b) Using a soft brush and solvent, thoroughly clean the cylin-
der block.
G35189

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22. INSPECT PISTON DIAMETER

(a) Using a micrometer, measure the piston diameter at right
angles to the piston center line, the indicated distance
from the piston end.
Distance: 9.3 mm (0.366 in.)
Piston diameter:
Standard 94.941 to 94.971 mm (3.7378 to 3.7390 in.)
Distance 9.3 mm
(0.366 in.) G37359
23. INSPECT PISTON OIL CLEARANCE

(a) Measure the cylinder bore diameter in the thrust directions (see step 20).
(b) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
0.019 to 0.052 mm (0.0007 to 0.0020 in.)
If the oil clearance is greater than the standard, replace all the pistons and rebore all the cylinders. If neces-
sary, replace the cylinder block.
HINT:
S Bore all the cylinders for the O/S piston outside diameter.
S Replace all the piston rings with ones to match the O/S pistons.
(c) If the oil clearance is greater than the standard.
(1) Prepare 4 new O/S pistons.
O/S 0.50 piston diameter:
95.441 to 95.451 mm (3.7575 to 3.7579 in.)
(2) Using a micrometer, measure the piston diameter at right angles to the piston center line, the
indicated distance from the piston end.
Distance: 9.3 mm (0.366 in.)
(3) Calculate the amount each cylinder is to be rebored as follows:
Size to be rebored = P + C − H
P = Piston diameter
C = Piston clearance:
0.019 to 0.052 mm (0.0007 to 0.0020 in.)
H = Allowance for honing: 0.02 mm (0.0008 in.) or less
(4) Bore and hone the cylinders to calculated dimensions.
Maximum honing: 0.02 mm (0.0008 in.)
NOTICE:
Excess honing will destroy the finished roundness.
24. 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:
No.1 0.020 to 0.075 mm (0.0008 to 0.0030 in.)
No.2 0.020 to 0.065 mm (0.0008 to 0.0026 in.)
Oil 0.020 to 0.070 mm (0.0008 to 0.0028 in.)
If the clearance is not as specified, replace the piston.
G37360

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25. 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 bot-
tom of the ring travel, 110 mm (4.33 in.) from the top of the
cylinder block.
110 mm
Piston Ring
G37361
(c) Using a feeler gauge, measure the end gap.

Standard end gap:
No.1 0.22 to 0.34 mm (0.0087 to 0.0134 in.)
No.2 0.45 to 0.57 mm (0.0177 to 0.0224 in.)
Oil 0.10 to 0.40 mm (0.0039 to 0.0157 in.)
Maximum end gap:
No. 1 0.90 mm (0.0354 in.)
G37362
No. 2 1.36 mm (0.0535 in.)
Oil 0.75 mm (0.0295 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 piston ring, rebore all the 4 cylinders or replace the cylinder
block.
26. INSPECT PISTON PIN OIL CLEARANCE

(a) Using a caliper gauge, measure the inside diameter of the
piston pin hole.
Piston pin hole inside diameter:
22.001 to 22.010 mm (0.8662 to 0.8665 in.)
G37363

14−71
(b) Using a micrometer, measure the piston pin diameter.

Piston pin diameter:
21.997 to 22.006 mm (0.8660 to 0.8664 in.)
6 mm
(0.24 in.)
31 mm
(1.22 in.)
6 mm (0.24 in.) G37364
(c) Using a caliper gauge, measure the inside diameter of the

connecting rod bushing.
Bushing inside diameter:
22.005 to 22.014 mm (0.8663 to 0.8667 in.)
(d) Subtract the piston pin diameter measurement from the
piton pin hole diameter measurement.
0.001 to 0.007 mm (0.00004 to 0.00028 in.)
G37365 Maximum oil clearance: 0.010 mm (0.0004 in.)
HINT:
If the oil clearance is greater than the maximum, replace the pis-
ton and piston pin as a set.

14−72
(e) Subtract the piston pin diameter measurement from the

bushing inside diameter measurement.
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Front Mark Maximum oil clearance: 0.025 mm (0.0010 in.)
(f) If the oil clearance is greater than the maximum, replace
the bushing. If necessary, replace the connecting rod and
piston pin as a set.
Piston Pin Hole
Inside Diameter
Mark
Connecting Rod
Bushing Inside Front Mark
Diameter Mark
G37367
27. INSPECT CONNECTING ROD

(a) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Check for bend.
Maximum bend:
0.03 mm (0.0012 in.) per 100 mm (3.94 in.)
If the bend is greater than the maximum, replace the connecting
rod sub−assy.
A54727
(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 sub−assy.
A54728
28. REMOVE CONNECTING ROD SMALL END BUSH

(a) Using SST and a press, press out the bush.
SST SST 09222−30010
A54717

14−73
29. INSPECT CONNECTING ROD BOLT

(a) Using vernier calipers, 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.
G37366
30. 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: 0.03 mm (0.0012 in.)
If the circle runout is greater than the maximum, replace the
crankshaft.
G37368
No.1 No.2 No.3 No.4 No.5

(b) Inspect the main journals.
(1) Using a micrometer, measure the diameter of each
main journal.
Standard journal diameter:
No.3 journal 59.981 to 59.994 mm (2.3615 to 2.3620 in.)
Except No.3 journal 59.987 to 60.000 mm (2.3619 to 2.3622 in.)
If the diameter is not as specified, check the oil clearance (see
step 31). 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:
0.005 mm (0.0002 in.)
If the taper and out−of−round is greater than the maximum, re-
G37369 place the crankshaft.
(c) Inspect the crank pin.

(1) Using a micrometer, measure the diameter of each
crank pin.
Diameter: 52.989 to 53.002 mm (2.0862 to 2.0867 in.)
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:
0.003 mm (0.0001 in.)
If the taper and out−of−round is greater than the maximum, re-
place the crankshaft.
G37370

14−74
31. INSPECT CRANKSHAFT OIL CLEARANCE

HINT:
S Keep the lower bearings and crankshaft bearing caps to-
gether.
S Arrange the thrust washers in the correct order.
S Keep the upper crankshaft bearings and upper thrust
washers together with the cylinder block.
(a) Clean each main journal and bearing.
(b) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearing.
(c) Place the crankshaft on the cylinder block.
Plastigage (d) Lay a strip of Plastigage across each journal.
G37376
(e) Install the 5 crankshaft bearing caps in their proper loca-

tions.
(f) Install the 5 crankshaft bearing caps with the 10 bolts (see
step 49).
NOTICE:
Do not turn the crankshaft.
(g) Remove the 10 bolts and 5 crankshaft bearing caps (see
step 6).
G37377

14−75
(h) Measure the Plastigage at its widest point.

Plastigage
Bearing Cap Standard
No.3 0.030 to 0.055 mm (0.0012 to 0.0022 in.)
Others 0.024 to 0.049 mm (0.0009 to 0.0019 in.)
If the oil clearance is greater than the maximum, replace the
crankshaft bearing.
HINT:
S If replacing the cylinder block, measure the bearing stan-
dard clearance.
S If replacing a bearing, first check the number on the cylin-
der block for the bearing’s respective journal. Then re-
place the bearing with one that has the same number.
Each bearing’s standard thickness is indicated by a 1, 2
or 3 mark on its surface.
Reference:
Cylinder block main journal bore diameter:
Mark Diameter
No.3
1 64.004 to 64.010 mm (2.5198 to 2.5201 in.)
2 64.011 to 64.016 mm (2.5201 to 2.5203 in.)
3 64.017 to 64.022 mm (2.5203 to 2.5206 in.)
No.1 No.5 Standard bearing center wall thickness:
No.2 No.4 Mark Thickness
1 1.987 to 1.990 mm (0.0782 to 0.0783 in.)
2 1.991 to 1.993 mm (0.0784 to 0.0785 in.)
3 1.994 to 1.996 mm (0.0785 to 0.0786 in.)
Mark 1, 2, 3
(i) Completely remove the Plastigage.
G37379
G37380 G39585
32. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Using vernier calipers, measure the minimum diameter of
the compressed thread at the measuring point.
Standard diameter:
10.76 to 10.97 mm (0.4236 to 0.4319 in.)
Minimum diameter: 10.66 mm (0.4197 in.)
If the diameter is less than the minimum, replace the bolt.
A86985
33. INSPECT NO.1 BALANCESHAFT

B
(a) Inspect the diameter of the journal.
A (1) Using a micrometer, measure the diameter of the
balanceshaft main journals.
Main journal diameter:
A 37.969 to 37.985 mm (1.4948 to 1.4955 in.)
B 37.449 to 37.465 mm (1.4744 to 1.4750 in.)
G37395

14−76
(b) Inspect the diameter of bearing.

B
(1) Using a cylinder gauge, measure the inside diame-
A ter of the balanceshaft bearing.
Bearing inside diameter:
A 38.025 to 38.045 mm (1.4970 to 1.4978 in.)
B 37.525 to 37.545 mm (1.4774 to 1.4781 in.)
(c) Inspect oil clearance.
(1) Subtract the balanceshaft main journal diameter
G37397 measurement from the balanceshaft bearing inside
diameter measurement.
A 0.040 to 0.076 mm (0.0016 to 0.0030 in.)
B 0.060 to 0.096 mm (0.0024 to 0.0038 in.)
If the oil clearance is greater than the maximum, replace the cyl-
inder block and balanceshaft.
34. INSPECT NO.2 BALANCESHAFT

B (a) Inspect the diameter of the journal.
(1) Using a micrometer, measure the diameter of the
A
balanceshaft main journals.
Main journal diameter:
A 37.969 to 37.985 mm (1.4948 to 1.4955 in.)
B 37.449 to 37.465 mm (1.4744 to 1.4750 in.)
G37396
(b) Inspect the diameter of bearing.

B
(1) Using a cylinder gauge, measure the inside diame-
A ter of the balanceshaft bearing.
Bearing inside diameter:
A 38.025 to 38.045 mm (1.4970 to 1.4978 in.)
B 37.525 to 37.545 mm (1.4774 to 1.4781 in.)
(c) Inspect oil clearance.
G37398 A 0.040 to 0.076 mm (0.0016 to 0.0030 in.)
B 0.060 to 0.096 mm (0.0024 to 0.0038 in.)
If the oil clearance is greater than the maximum, replace the cyl-
inder block and balanceshaft.

14−77
35. INSTALL TIGHT PLUG

Adhesive NOTICE:
If water leaks from the tight plug or the plug corrodes, re-
place it.
(a) Apply adhesive around the tight plugs.
Adhesive:
Part No. 08833−00070, THREE BOND 1324 or equiva-
lent.
A58129
(b) Using SST and a hammer, tap in new tight plugs as shown
SST in the illustration.
(c) Using SST, tap in the 8 tight plugs A and C.
SST 09950−60010 (09951−00350), 09950−70010
(09951−07100)
(d) Using SST, tap in the tight plug B.
SST 09950−60010 (09951−00300), 09950−70010
(09951−07100)
G37381

14−78
(e) Using SST, tap in the 3 tight plugs D.

SST 09950−60010 (09951−00400), 09950−70010
(09951−07100)
Front Side
Intake Side
B A
Rear Side
Exhaust Side
D C
1.0 mm
(0.039 in.)
G37382

14−79
36. INSTALL STUD BOLT

(a) Using an E7 torxâ socket wrench, install the stud bolts B and D.
Torque: 7.5 N×m (77 kgf×cm, 66 in.×lbf) for stud bolts B and D
(b) Using an E8 torxâ socket wrench, install the stud bolts A.
Torque: 7.5 N×m (77 kgf×cm, 66 in.×lbf) for stud bolts A
(c) Apply adhesive to the hole for the stud bolt C on the cylinder block. Using an E7 torxâ socket wrench,
install the stud bolts C.
Torque: 7.5 N×m (77 kgf×cm, 66 in.×lbf) for stud bolt C
NOTICE:
If the stud bolt is deformed or the threads are damaged, replace it.
Front Side Lower Side
A
D
12 mm
(0.47 in.)
Exhaust Side
C
85 mm
(3.35 in.)
12 mm
(0.47 in.)
A
18 mm
25 mm (0.71 in.)
(0.98 in.)
55 mm 60 mm 18 mm
(2.17 in.) (2.36 in.) (0.71 in.) 33 mm
(1.30 in.)
12 mm 12 mm 13 mm
(0.47 in.) (0.47 in.) (0.51 in.)
B C D G37383

14−80
Rear Side 37. INSTALL STRAIGHT PIN

(a) Using a plastic−faced hammer, tap in new straight pins to
the cylinder block.
A
13 mm 5.5 mm
(0.51 in.) (0.22 in.)
A (f10) B (f6)
G37384
38. INSTALL RING PIN

(a) Using a plastic−faced hammer, tap in new ring pins to the cylinder block.
Front Side Lower Side
3.5 to 4.5 mm 7.0 to 9.0 mm

(0.14 to 0.18 in.) (0.28 to 0.35 in.)
Upper Side
11 mm (0.43 in.)
14 mm (0.55 in.)
9 mm
(0.35 in.) 20 mm
A (0.79 in.)
C
7.5 to 9.5 mm
(0.30 to 0.37 in.)
15 mm (0.59 in.)
14 mm
B (0.55 in.)
B
G37385

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39. INSTALL BALANCESHAFT DRIVEN GEAR NO.2

L1
NOTICE:
(b) Install the balanceshaft thrust washer No.2 (L 1) and ba-
L2
lanceshaft driven gear No.2 (L 2).
(c) Install and torque the bolt.
Torque: 36 N×m (365 kgf×cm, 26 ft×lbf)
G37394
40. INSTALL NO.2 BALANCESHAFT

(a) Install the balanceshaft to the cylinder block.
NOTICE:
When installing the balanceshaft, make sure to support the
G37393
(b) Install and torque the 2 bolts.

G37392
41. INSTALL BALANCESHAFT DRIVEN GEAR NO.1

L3 L2
NOTICE:
(b) Install the balanceshaft thrust spacer (L 1), balanceshaft
L4
L1 thrust washer No.1 (L 2), sliding key (L 3) and balance-
shaft driven gear No.1 (L 4).
(c) Install and torque the bolt.
G37391 Torque: 36 N×m (365 kgf×cm, 26 ft×lbf)
42. INSTALL NO.1 BALANCESHAFT

(a) Install the No.1 balanceshaft to the cylinder block.
NOTICE:
When installing the balanceshaft, make sure to support the
G37390

14−82
(b) Install and torque the bolt.

G37389
43. INSTALL CYLINDER BLOCK WATER DRAIN COCK

SUB−ASSY
(a) Apply adhesive around the drain cock.
G37320
(b) Install the cylinder block water drain cock as shown in the
illustration.
Torque: 25 N×m (250 kgf×cm, 18 in.×lbf)
(c) Install the water drain cock plug to the water drain cock
sub−assy.
Torque: 13 N×m (130 kgf×cm, 9 in.×lbf)
Upper Side
Front
30_
60_
Target
Permit Direction
Direction
G37321
44. INSTALL SUB−ASSY OIL NOZZLE NO.1

(a) Using an E7 torxâ socket wrench, install the oil nozzles.
Torque: 7.0 N×m (71 kgf×cm, 62 in.×lbf)
G37357

14−83
45. INSTALL CONNECTING ROD SMALL END BUSH

(a) Align the oil holes of a new bush and the connecting rod.
Oil
Hole
A54732
(b) Using SST and a press, press in the bush.

SST 09222−30010
SST
A54717
(c) Using a pin hole grinder, hone the bush to obtain the stan-
dard specified clearance (see step 26) between the bush
and piston pin.
A54733
(d) Check that the piston pin fits at normal room temperature.
(1) Coat the piston pin with engine oil, and push it into
the connecting rod with your thumb.
A54734
46. INSTALL W/PIN PISTON SUB−ASSY

(a) Assemble the piston and connecting rod.
(1) Using a screwdriver, install a new snap ring at one
end of the piston pin hole.
Service Hole
G37386

14−84
(2) Gradually heat the piston to approximately 80 to

80_C to 90_C
90_C (176 to 194_F).
G37355
(3) Coat the piston pin with engine oil.

Front Mark
(4) Align the front marks of the piston and connecting
rod, and push in the piston pin with your thumb.
HINT:
The piston and pin are a matched set.
Front Mark
G37387
(5) Check the fitting condition between the piston and

piston pin by trying to move the piston back and
forth on the piston pin.
G35197
(6) Using a screwdriver, install a new snap ring at the

other end of the piston pin hole.
Service Hole
G37386
47. INSTALL PISTON RING SET

(a) Install the oil ring expander by hand.
(b) Using a piston ring expander, install the oil ring rail.
G37354

14−85
Code Mark (1N)

(c) Using a piston ring expander, install the 2 compression
Code Mark (2N)
rings so that the painted marks are positioned as shown
in the illustration.
HINT:
S Install the compression ring No.1 with the code mark (1N)
facing upward.
S Install the compression ring No.2 with the code mark (2N)
facing upward.
G38405
Oil Ring (d) Position the piston rings so that the ring ends are as
Expander shown in the illustration.
NOTICE:
Do not align the ring ends.
48. INSTALL CRANKSHAFT BEARING
NOTICE:
S Do not apply engine oil to the bearing’s contact area
No.1 Ring and and backside.
Oil Ring S The crankshaft bearing cap bolt is tightened in 2 pro-
No.2 Ring
gressive steps.
No.1 Ring (a) Clean the main journal, and the both surfaces of the bear-
No.2 Ring ing.
Oil Ring Expander
Oil Ring
G37401
(b) Install the upper bearing.

(1) Install the upper bearing to the cylinder block as
shown in the illustration.
NOTICE:
Do not apply engine oil to the bearing’s contact area and
backside.
Upper Bearing
Cylinder Block
CORRECT INCORRECT
G38408

14−86
(c) Install the lower bearing.

(1) Install the lower bearing to the bearing cap.
A
(2) Using vernier calipers, measure the distance be-
tween the bearing cap’s edge and the lower bear-
ing’s edge.
Dimension (A − B): 0.3 mm (0.0118 in.) or less
HINT:
B
Journal Dimension (A)
G37372 #1, 5 3.75 mm (0.1476 in.)
#3 1.75 mm (0.0689 in.)
#2, 4 2.75 mm (0.1083 in.)
NOTICE:
Do not apply engine oil to the bearing’s contact area and
backside.
(d) With the upper bearing and lower bearing installed, use
a plastic−faced hammer to install the bearing caps to the
cylinder block.
NOTICE:
Make sure that the bearing caps are installed in the correct
positions and direction.
(e) Using vernier calipers, measure the amount of misalign-

ment between the upper bearing and lower bearing, as
A
shown in the illustration.
Standard: 0.9 mm (0.035 in.) or less
(f) Remove the bearing cap.
Misalignment
A97959

14−87
(g) Install the crankshaft thrust washer upper to the cylinder

block.
(1) Install the 2 thrust washers under the No.3 journal
position of the cylinder block with the oil grooves
facing outward.
NOTICE:
Be careful when installing the thrust bearing upper and
lower as they are similar but cannot be interchanged.
Oil Groove
G37374
Lower Bearing (h) Install the 2 thrust washers on the No.3 bearing cap with
Claw the grooves facing outward.
NOTICE:
Be careful when installing the thrust bearing upper and
lower as they are similar but cannot be interchanged. The
bearing lower has a claw as shown in the illustration.
(i) Apply engine oil to the lower bearing.
Oil Groove Lower Bearing 49. INSTALL CRANKSHAFT
Claw G37375 (a) Apply engine oil to the upper bearing, then place the
crankshaft on the cylinder block.
Engine Front (b) Install the 5 crankshaft bearing caps in their proper loca-
tions.
G37377
(c) Install the crankshaft bearing cap bolts.

7 3 1 5 9 HINT:
The main bearing cap bolts are tightened in 2 progressive
steps.
(d) Step 1
(1) Install and uniformly tighten the 10 main bearing
8 4 6 10 cap bolts in the sequence shown in the illustration.
2
G37378 If any of the main bearing cap bolts does not meet the torque
specification, replace the main bearing cap bolt.

14−88
(e) Step 2
Step 2 Paint Mark
90_
(1) Mark the front of the bearing cap bolts with paint.
Engine Front (2) Retighten the bearing cap bolts by 90_ in the order
above.
(3) Check that the painted mark is now at a 90_ angle
to the front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance (see step 5).
G38409
50. INSTALL CONNECTING ROD BEARING

Claw (a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the connecting rod.
G37399 51. INSTALL PISTON SUB−ASSY W/CONNECTING ROD
(a) Apply engine oil to the cylinder walls, the pistons, and the
surfaces of connecting rod bearings.
Oil Ring (b) Position the piston rings so that the ring ends are as
Expander shown in the illustration.
NOTICE:
Do not align the ring ends.
No.1 Ring and

Oil Ring
No.2 Ring
No.1 Ring
No.2 Ring
Oil Ring Expander
Oil Ring
G37401
(c) Using a piston ring compressor, push the correctly num-

Front Mark bered piston and connecting rod assembly into the cylin-
der with the front mark of the piston facing forward.
(d) Match the numbered connecting rod cap with the con-
necting rod.
NOTICE:
Front S Match the numbered connecting rod cap with the con-
necting rod.
G37400

14−89
(e) Check that the front mark of the connecting rod cap is fac-
Front Mark
ing forward.
(f) Apply a light coat of engine oil to the threads and under
the heads of the connecting rod cap bolts.
G37347
(g) Install and alternately tighten the bolts of the connecting

rod cap in several steps.
G37348
Painted Mark (h) Mark the front side of each connecting cap bolt with paint.
90_ (i) Retighten the cap bolts by 90_ as shown.
(j) Check that the painted mark is now at a 90˚ angle to the
front.
Front (k) Check that the crankshaft turns smoothly.
(l) Check the connecting rod thrust clearance (see step 1).
G37349

Overhaul: 1. Inspect Connecting Rod Thrust Clearance

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14−61

ENGINE MECHANICAL − CYLINDER BLOCK ASSY (2TR−FE)

1. INSPECT CONNECTING ROD THRUST CLEARANCE

2TR−FE ENGINE REPAIR MANUAL (RM1152E)

(h) Install the connecting rod cap. (see step 51)

(j) Measure the Plastigage at its widest point.

3. REMOVE PISTON SUB−ASSY W/CONNECTING ROD

2TR−FE ENGINE REPAIR MANUAL (RM1152E)

4. REMOVE CONNECTING ROD BEARING

5. INSPECT CRANKSHAFT THRUST CLEARANCE

(c) Remove the upper bearings and upper thrust washers

7. REMOVE CRANKSHAFT BEARING

2TR−FE ENGINE REPAIR MANUAL (RM1152E)

8. REMOVE PISTON RING SET

9. REMOVE CYLINDER BLOCK WATER DRAIN COCK

10. REMOVE W/PIN PISTON SUB−ASSY

(b) Disconnect the connecting rod from the piston.

(2) Gradually heat the piston to approximately 80 to

2TR−FE ENGINE REPAIR MANUAL (RM1152E)

(3) Using a brass bar and plastic−faced hammer, lightly

11. CLEAN W/PIN PISTON SUB−ASSY

(c) Using solvent and a brush, thoroughly clean the piston.

12. REMOVE SUB−ASSY OIL NOZZLE NO.1

2TR−FE ENGINE REPAIR MANUAL (RM1152E)

13. INSPECT SUB−ASSY OIL NOZZLE NO.1

14. INSPECT BALANCE SHAFT THRUST CLEARANCE

15. REMOVE NO.1 BALANCESHAFT

(b) Remove the balanceshaft from the cylinder block.

16. REMOVE BALANCESHAFT DRIVEN GEAR NO.1

2TR−FE ENGINE REPAIR MANUAL (RM1152E)

17. REMOVE NO.2 BALANCESHAFT

(b) Remove the balanceshaft from the cylinder block.

18. REMOVE BALANCESHAFT DRIVEN GEAR NO.2

19. INSPECT CYLINDER BLOCK FOR FLATNESS

2TR−FE ENGINE REPAIR MANUAL (RM1152E)

(b) Visually check the cylinder for vertical scratches.

20. INSPECT CYLINDER BORE

(b) Inspect the cylinder ridge.

21. CLEAN CYLINDER BLOCK

2TR−FE ENGINE REPAIR MANUAL (RM1152E)

22. INSPECT PISTON DIAMETER

23. INSPECT PISTON OIL CLEARANCE

24. INSPECT RING GROOVE CLEARANCE

2TR−FE ENGINE REPAIR MANUAL (RM1152E)

25. INSPECT PISTON RING END GAP

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

26. INSPECT PISTON PIN OIL CLEARANCE

2TR−FE ENGINE REPAIR MANUAL (RM1152E)

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

6 mm (0.24 in.) G37364

(c) Using a caliper gauge, measure the inside diameter of the

2TR−FE ENGINE REPAIR MANUAL (RM1152E)

(e) Subtract the piston pin diameter measurement from the

27. INSPECT CONNECTING ROD

(2) Check for twist.

28. REMOVE CONNECTING ROD SMALL END BUSH

2TR−FE ENGINE REPAIR MANUAL (RM1152E)

29. INSPECT CONNECTING ROD BOLT

30. INSPECT CRANKSHAFT