Inspection and Replacement

CYLINDER BLOCK

COMPONENTS:

INSPECTION
1. INSPECT CYLINDER BLOCK FOR FLATNESS
2. INSPECT CYLINDER BORE
3. INSPECT RING GROOVE CLEARANCE
4. INSPECT PISTON RING END GAP
5. INSPECT PISTON WITH PIN SUB-ASSEMBLY
6. INSPECT PISTON OIL CLEARANCE
7. INSPECT PISTON PIN OIL CLEARANCE
8. INSPECT CONNECTING ROD SUB-ASSEMBLY
9. INSPECT CRANKSHAFT
10. INSPECT CRANKSHAFT OIL CLEARANCE
11. INSPECT CONNECTING ROD OIL CLEARANCE
12. INSPECT CONNECTING ROD BOLT
13. INSPECT CRANKSHAFT BEARING CAP SET BOLT

REPLACEMENT
1. REPLACE STUD BOLT

NOTICE: If a stud bolt is deformed or the threads are damaged, replace it.

(a) Remove the stud bolts.
(b) Install new stud bolts.
Torque:
for stud bolt A and B 11 N*m (112 kgf*cm, 8 ft.*lbf)
for stud bolt C 4.0 N*m (41 kgf*cm, 35 in.*lbf)

2. REPLACE STRAIGHT PIN

NOTICE: It is not necessary to remove the straight pin unless it is being replaced.

(a) Remove the straight pins.
(b) Using a plastic-faced hammer, tap in new straight pins to the cylinder block.

Standard protrusion:

3. REPLACE CYLINDER BLOCK TIGHT PLUG

NOTICE: If water leaks from the tight plug or the plug corrodes, replace it.

(a) Remove the tight plugs.

(b) Apply adhesive around new tight plugs.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(c) Using SST and a hammer, tap in the tight plugs to the specified depth.
SST 09950-60010 (09951-00350), 09950-70010 (09951-07150)
Specified depth: 0.2 to 1.2 mm (0.00787 to 0.0472 in.)

4. REPLACE OIL JET

NOTICE: It is not necessary to remove the oil jet unless it is being replaced.

(a) Using a screwdriver and hammer, tap out the oil jet.

(b) Using a screwdriver and hammer, tap in a new oil jet as shown in the illustration.

5. REPLACE CONNECTING ROD SMALL END BUSH
(a) Using SST and a press, press out the bush.
SST 09222-30010

(b) Align the oil holes of a new bush and the connecting rod.

(d) Using a pin hole grinder, hone the bush to obtain the standard specified clearance between the bush and piston pin.
Standard oil clearance: 0.005 to 0.011 mm (0.000197 to 0.000433 in.)

HINT: Check that the piston pin fits at a normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with a thumb.