14–42

ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

CYLINDER BLOCK (1AZ–FE)

140DW–01

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:
0.160 – 0.362 mm (0.0063 – 0.0143 in.)
Maximum thrust clearance: 0.362 mm (0.0143 in.)
(b) If the thrust clearance is greater than maximum, replace
the connecting rod assembly(s). If necessary, replace the
A13845 crankshaft.

2. INSPECT CONNECTING ROD OIL CLEARANCE

HINT:
The connecting rod cap bolts are tightened in 2 progressive
steps.
(a) Check the matchmarks on the connecting rod and cap are
aligned to ensure correct reassembly.
HINT:
The matchmarks on the connecting rods and caps are for en-
A13846 suring correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Clean the crank pin and bearing.
(d) Check the crank pin and bearing for pitting and scratches.

(e) Lay a strip of plastigage on the crank pin.

A13848

(f) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
(g) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(h) Tighten the bolts in several passes by the specified
torque.
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)

A13874

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ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

(i) Mark the front of the connecting rod cap bolts with paint.
Paint
Mark
(j) Retighten the cap bolts by 90 as shown in the illustration.
90
Engine Front NOTICE:
Do not turn the crankshaft.
(k) Remove the 2 bolts, connecting rod cap and lower bear-
ing.

A57501

(l) Measure the plastigage at its widest point.

Standard oil clearance:
0.024 – 0.048 mm (0.0009 – 0.0019 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
NOTICE:
Completely remove the plastigage.

A13850

(m) If replacing a bearing, replace it with one having the same

number as marked on the connecting rod. There are 3
sizes of standard bearings, marked ”1”, ”2” and ”3” ac-
Mark
1, 2 or 3 cordingly.
HINT:
Standard bearing center wall thickness.
Mark 1 1.485 – 1.488 mm (0.0585 – 0.0586 in.)
Mark
Mark 2 1.488 – 1.491 mm (0.0586 – 0.0587 in.)
1, 2 or 3
A57505 Mark 3 1.491 – 1.494 mm (0.0587 – 0.0588 in.)

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
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
A13469 correct order.

4. REMOVE CONNECTING ROD BEARING

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ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

5. REMOVE PISTON RING SET

(a) Using a piston ring expander, remove the 2 compression

rings.
(b) Remove the 2 side rails and oil ring by hand.

A36647

6. REMOVE PISTON PIN HOLE SNAP RING

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

A13478

7. REMOVE PISTON

(a) Gradually heat the piston to 80 – 90 C (176 – 194 F).

A01178

(b) Using a plastic–faced 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 pistons, pins, rings, connecting rods and
bearings in the correct order.

A01179

8. 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:
0.040 – 0.240 mm (0.0016 – 0.0094 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
(b) If the thrust clearance is greater than maximum, replace
the thrust washers as a set.
A13851 Thrust washer thickness:
1.930 – 1.980 mm (0.0760 – 0.0780 in.)
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ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

2 9. REMOVE CRANKSHAFT
6
10
(a) Uniformly loosen and remove the 10 bearing cap sub–as-
8
sembly bolts, in several passes, in the sequence shown.
4
1 (b) Remove the bearing cap and crankshaft.
5
9
7
3
A56226

10. REMOVE CRANKSHAFT THRUST WASHER UPPER

11. REMOVE CRANKSHAFT BEARING

NOTICE:
Arrange the bearings in the correct order.
12. REMOVE CRANKSHAFT BEARING NO.2

NOTICE:
Arrange the main bearings and thrust washers in the correct order.
13. REMOVE STUD BOLT

14. 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.)

A36648

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ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

15. 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:
86.000 – 86.013 mm (3.3858 – 3.3863 in.)
Maximum diameter: 86.013 mm (3.3863 in.)
(b) If the diameter is greater than maximum, replace the cyl-
inder block.

Thrust Direction

Front

Axial Direction

A
B 10 mm
(0.39 in.)A57506

16. 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:
85.927 – 85.937 mm (3.3829 – 3.3833 in.)
30.4 mm
(1.197 in.)
A56232

17. INSPECT PISTON CLEARANCE

(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.063 – 0.086 mm (0.0025 – 0.0034 in.)
Maximum oil clearance: 0.1 mm (0.0039 in.)
(b) If the clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder
block.

18. 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:
No. 1 0.020 – 0.070 mm (0.0008 – 0.0028 in.)
No. 2 0.020 – 0.060 mm (0.0008 – 0.0024 in.)
Oil ring (side rail )
w/ TWC 0.070 – 0.150 (0.0028 – 0.0059 in.)
A36650 w/o TWC 0.060 – 0.140 (0.0024 – 0.0055 in.)

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ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

19. 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.

110 mm

Piston Ring
A57507

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

Standard end gap:
No. 1 0.30 – 040 mm (0.0118 – 0.0157 in.)
No. 2 0.47 – 0.62 mm (0.0185 – 0.0244 in.)
Oil (side rail) 0.10 – 0.35 mm (0.0039 – 0.0138 in.)
Maximum end gap:
No. 1 0.89 mm (0.0350 in.)
No. 2 1.37 mm (0.0539 in.)
EM2552 Oil (side rail) 0.73 mm (0.0287 in.)

20. INSPECT PISTON PIN OIL CLEARANCE

(a) Using caliper gauge, measure the inside diameter of the
piston bushing.
Bushing inside diameter:
22.001 – 22.010 mm (0.8662 – 0.8665 in.)
Bushing inside diameter
Mark mm (in.)
A 22.001 – 22.004 (0.8662 – 0.8663)
A13490 B 22.004 – 22.007 (0.8663 – 0.8664)
C 22.007 – 22.010 (0.8664 – 0.8665)

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

Piston pin diameter:
21.997 – 22.009 mm (0.8660 – 0.8665 in.)
Piston pin diameter
Mark Color mm (in.)
21.997 – 22.000
A Blue
(0.8660 – 0.8661)
22.000 – 22.003
B Green
(0.8661 – 0.8663)
EM0227
22.003 – 22.006
C Colorless
(0.8663 – 0.8664)
22.006 – 22.009
̈́
(0.8664 – 0.8665)

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ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

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

connecting rod bushing.
Bushing inside diameter:
22.005 – 22.014 mm (0.8663 – 0.8667 in.)
Bushing inside diameter
Mark mm (in.)
A 22.005 – 22.008 (0.8663 – 0.8665)
B 22.008 – 22.011 (0.8665 – 0.8666)
A01185 C 22.011 – 22.014 (0.8666 – 0.8667)
(d) Subtract the piston pin diameter measurement from the
piton pin hole diameter measurement.
Standard oil clearance:
0.001 – 0.007 mm (0.00004 – 0.00028 in.)
Maximum oil clearance: 0.010 mm (0.0020 in.)

(e) If the oil clearance is greater than maximum, replace the

connecting rod. If necessary, replace the piston and pis-
ton pin as a set.
Piston Bushing
(f) Subtract the piston pin diameter measurement form the
Inside Diameter
Mark
bushing inside diameter measurement.
Front Mark Standard oil clearance:
0.005 – 0.011 mm (0.0002 – 0.0004 in.)
Maximum oil clearance: 0.010 mm (0.0020 in.)
(g) If the oil clearance is greater than maximum, replace the
connecting rod. If necessary, replace the connecting rod
and piston pin as a set.
Piston Pin
Diameter Front Mark
Color

Connecting Rod
Bushing Inside Diameter Mark A57508

21. 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.)
(b) If out–of alignment is greater than maximum, replace the
Z00064 connecting rod assembly.

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ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

(1) Check for twist.

Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
(c) If twist is greater than maximum, replace the connecting
rod assembly.

Z00065

22. INSPECT CONNECTING ROD BOLT

(a) Using a vernier calipers, measure the tension portion di-

ameter of the bolt.
Standard diameter: 7.2 – 7.3 mm (0.283 – 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)
(b) If the diameter is less than minimum, replace the bolt.

A01470

23. INSPECT CRANKSHAFT

(a) Using a dial indicator and V–blocks, measure the circle

runout, ash shown in the illustration.
Maximum circle runout: 0.03 mm (0.0012 in.)

A13859

(b) Using a micrometer, measure the diameter of each main

journal.
Diameter: 54.988 – 55.000 (2.1648 – 2.1654 in.)
(c) Check each main journal for taper and out–of–round as
shown.
Maximum taper and out– of –round:
0.003 mm (0.0001 in.)
Mark mm (in.)
0 54.998 – 55.000 (2.16528 – 2.16535)
1 54.996 – 54.998 (2.16520 – 2.16528)
2 54.994 – 54.996 (2.16512 – 2.16520)
3 54.992 – 54.994 (2.16504 – 2.16512)
4 54.990 – 54.992 (2.16496 – 2.16504)
5 54.988 – 54.990 (2.16490 – 2.16496)

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ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

(d) Using a micrometer, measure the diameter of each crank

pin.
Diameter: 47.990 – 48.000 mm (1.8894 – 1.8898 in.)
(e) Check each crank pin for taper and out–of–round as
shown.
Maximum taper and out–of–round:
0.003 mm (0.0001 in.)

ZF6928

24. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Using vernier calipers, measure the tension portion diam-

eter of the bolt.
Standard diameter: 7.5 – 7.6 mm (0.295 – 0.299 in.)
Minimum diameter: 7.2 mm (0.283 in.)
If the diameter is less than minimum, replace the bolt.

EM6347 A15065

25. INSTALL RING PIN

(a) Using a plastic–faced hammer, tap into the ring pin.
Standard protrusion:
Ring pin A 6 mm (0.236 in.)
Ring pin B 5 mm (0.197 in.)

Upper Side Bottom Side

B

B
14 13
6 (Ring Pin A)
5 (Ring Pin B)
12 12

A B

A57509

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ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

26. INSPECT CRANKSHAFT OIL CLEARANCE

NOTICE:

Clean the backside of the bearing and the bearing
surface of the bearing cap and let not stick the oils
and fats.

The bearing cap bolts are tightened in 2 progressive
steps.
(a) Clean each main journal and bearing.
A53029 (b) Install the upper bearing with an oil groove on cylinder
block.
(c) Install the lower bearing on the bearing cap sub assem-
bly.
(d) Place the crankshaft on the cylinder block.

(e) Lay a strip of plastigage across each journal.

A13854

(f) Examine the front marks and install the bearing caps on
the cylinder block.
(g) Apply a light coat of engine oil on the threads and under
the bearing cap bolts.

A13868

(h) Tighten the bolts in several passes, in the sequence

9 shown, by the specified torque.
1
5 Torque: 20 N
m (205 kgf
cm, 15 ft
lbf)
3 (i) Retighten the bolts in several passes, in the sequence
7 7 10 shown, by the specified torque.
6 Torque: 40 N
m (410 kgf
cm, 30 ft
lbf)
2
4
8
A13987

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ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

(j) Mark the front of the bearing cap bolts with paint.
Paint
(k) Retighten the bearing cap bolts by 90
in the numerical
90
Mark
Engine Front order shown.
(l) Check that the painted mark is now at a 90
angle to the
front.
NOTICE:
Do not turn the crankshaft.
(m) Remove the bearing cap.
A57501

(n) Measure the plastigage at its widest point.

Standard oil clearance:
0.017 – 0.040 mm (0.0007 – 0.0016 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
NOTICE:
Completely remove the plastigage.

A13855

(o) If using a standard bearing, replace it with one having the

same number. If the number of the bearing cannot be de-
termined, select the correct bearing by adding together
the numbers imprinted on the cylinder block and crank-
shaft, then selecting the bearing with the same number as
the total. There are 4 sizes of standard bearings, marked
”1”, ”2”, ”3” and ”4” accordingly.
Cylinder block
(A)
0–2 3–5 6–8 9 – 11
+
Crankshaft (B)
Use bearing ”1” ”2” ”3” ”4”
HINT:
EXAMPLE
Cylinder block ”4” (A) + Crankshaft ”3” (B) =
Total number 7 (Use bearing ”3”)

A13856

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ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

Reference:
Item Mark mm (in.)
0 59.000 – 59.002 (2.32283 – 2.32291)
1 59.003 – 59.004 (2.32295 – 2.32299)
2 59.005 – 59.006 (2.32303 – 2.32307)
Cylinder block main journal bore diameter (A) 3 59.007 – 59.009 (2.32311 – 2.32318)
4 59.010 – 59.011 (2.32322 – 2.32326)
5 59.012 – 59.013 (2.32330 – 2.32334)
6 59.014 – 59.016 (2.32338 – 2.32346)
0 54.998 – 55.000 (2.16527 – 2.16535)
1 54.996 – 54.998 (2.16519 – 2.16527)
2 54.994 – 54.996 (2.16511 – 2.16519)
Crankshaft main journal diameter (B)
3 54.992 – 54.994 (2.16503 – 2.16511)
4 54.990 – 54.992 (2.16496 – 2.16504)
5 54.988 – 54.990 (2.16488 – 2.16496)
1 1.993 – 1.996 (0.07846 – 0.07858)
2 1.996 – 1.999 (0.07858 – 0.07870)
Standard bearing center wall thickness
3 1.999 – 2.002 (0.07870 – 0.07882)
4 2.002 – 2.005 (0.07882 – 0.07894)

27. INSTALL TIGHT PLUG

(a) Apply adhesive around tight plugs.
Adhesive: Part No. 08833–00070, THREE BOND 1324
or equivalent.
(b) Using SST, into the tight plugs as shown in the illustration.
SST 09950–60010 (09951–00200), 09950–70010
(09951–07100)
Standard depth:
Engine front 1.7 – 2.7 mm (0.067 – 0.106 in.)
Engine rear 2.2 – 3.2 mm (0.087 – 0.126 in.)

Engine Front Engine Rear

A57510

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ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

28. INSTALL STUD BOLT

(a) Install the stud bolts as shown in the illustration.
Torque:
Stud bolt A 5.0 N
m (51 kgf
cm, 44 in.
lbf)
Stud bolt B 10N
m (97 kgf
cm, 84 in.
lbf)
Stud bolt C 5.0N
m (51 kgf
cm, 44 in.
lbf)

Front Side C Exhaust Side

16

B
84

18 14
31.5 27.5
20
9 9

A (M6) B (M10) C (M6)

A57547

29. INSTALL STRAIGHT PIN

(a) Using a plastic–faced hammer, tap into the straight pin.
Standard protrusion
Pin A 7.5 mm (0.295 in.)
Pin B 12 mm (0.472 in.)

Back Side Bottom Side Front Side

A
A
B

A
B
A

10
8
7.5 (Pin A)
12 (Pin B)
22
15

A B
A57512
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ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

30. INSTALL PISTON

(a) Using a small screwdriver, install a new snap ring at one

end of the piston pin hole.
(b) Gradually hat the piston to 80 – 90
C (176 – 194
F).

P12418 A32958

(c) Align the front marks on the piston with connecting rod,
and push in the piston with your thumb.
Front Mark (d) Using a small screwdriver, install a new snap ring on the
other end of the piston pin hole.
Front Mark

A57513

31. INSTALL PISTON RING SET

(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the point mark facing right side.
NOTICE:
Install the compression ring No. 2 with the code mark (2N)
facing upward.

Upward

No. 1

Painted Mark

No. 2

Code Mark (2N)

A57514

(c) Position the piston rings so that the ring ends are as
No. 1 and
Expander Side Rail Lower shown.

Front

Side Rail Upper No. 2

Compression
A57515

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ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

32. INSTALL CRANKSHAFT BEARING

(a) Install the upper bearing with an oil groove on cylinder

block.
NOTICE:
Clean the back side of the bearing and the bearing surface
of the cylinder block and let not stick the oils and fats.

A53029

33. INSTALL CRANKSHAFT BEARING NO.2

(a) Install the lower bearing on bearing cap.

NOTICE:
Clean the back side of the bearing and the bearing surface
of the bearing cap and let not stick the oils and fats.

A33379

34. INSTALL CRANKSHAFT THRUST WASHER UPPER

(a) Install the 2 thrust washers under the No. 3 journal posi-
tion of the cylinder block with the oil grooves facing out-
ward.

A13501

35. INSTALL CRANKSHAFT

(a) Apply engine oil to upper bearing and install the crank-
shaft on the cylinder block.
(b) Apply engine oil to lower bearing.
(c) Examine the front marks and install the bearing caps on
the cylinder block.
(d) Apply a light coat of engine oil on the threads and under
the bearing cap bolts.

A13868

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(e) Tighten the blots in several passes, in the sequence

9 shown, by the specified torque.
1
5 Torque: 20 N
m (205 kgf
cm, 15 ft
lbf)
3 (f) Tighten the bolts in several passes, in the sequence
7 7 10 shown, by the specified torque.
6 Torque: 40 N
m (410 kgf
cm, 30 ft
lbf)
2
4
8
A13987

(g) Mark the front of the bearing cap bolts with paint.
Paint (h) Retighten the bearing cap bolts by 90_ in the numerical
90_ Mark
Engine Front order shown.
(i) Check that the painted mark is now at a 90_ angle to the
front.
(j) Check the crankshaft turns smoothly.

A57516

36. INSTALL CONNECTING ROD BEARING

Claw
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
NOTICE:
Clean the back side of the bearing and the bearing surface
of the bearing cap and let not stick the oils and fats.

A57517

37. INSTALL PISTON

NOTICE:
The connecting rod cap bolts are tightened in 2 progres-
sive steps.
(a) Apply engine oil to the cylinder walls, the pistons, and the
surfaces of connecting rod bearings.
(b) Check the position of the piston ring ends.

(c) Using a piston ring compressor, push the correctly num-

Front Mark bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
NOTICE:
Match the numbered connecting rod cap with the connect-
ing rod.
Front

A57518

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ENGINE MECHANICAL – CYLINDER BLOCK (1AZ–FE)

(d) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
(e) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(f) Tighten the bolts in several passes by the specified
torque.
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)
(g) Mark the front of the connecting cap blots with paint.
A13874

(h) Retighten the cap bolts by 90
as shown in the illustration.

Paint (i) Check that the crankshaft turns smoothly.
90
Mark
Engine Front SST 09011–38121, 99999–60012

A57516

1AZ–FE ENGINE REPAIR MANUAL (RM865E)