Part 1

CYLINDER BLOCK ASSY (1NZ-FXE)
OVERHAUL
1. INSPECT CONNECTING ROD THRUST CLEARANCE





a. Using a dial indicator, measure the thrust clearance of the connecting rod while moving the connecting rod back and forth.
Standard thrust clearance: 0.16 to 0.36 mm (0.0063 to 0.0142 inch)
Maximum thrust clearance: 0.36 mm (0.0142 inch)
If the thrust clearance is greater than maximum, replace the connecting rod.
2. INSPECT CONNECTING ROD OIL CLEARANCE
a. Put the cylinder number on the connecting rod and connecting rod cap with paint.

HINT: Take step (a) so that the connecting rod and connecting rod cap can be returned to the original locations when reassembling.





b. Using SST, remove the 2 bolts.
SST 09205-16010
c. Remove the connecting rod cap from the connecting rod.
d. Clean the bearing, connecting rod end and crank pin.
e. Check that the bearing and crank pin are not excessively worn or scratched.





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





g. Check the front marks of the connecting rod and connecting rod cap, then install the connecting rod cap to the connecting rod
h. Apply a light coat of engine oil to the threads and contact surface of the bolts.





i. Using SST,temporarily tighten the bolts in several steps, then retighten them with the specified torque.
SST 09205-16010
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)





j. Mark the front of the connecting cap bolts with paint.
k. Retighten the cap bolts by 90° as shown in the illustration.

NOTICE: Do not turn the crankshaft when measuring.





l. Remove the connecting rod cap, then measure the Plastigage at its widest point.
Standard oil clearance: 0.016 to 0.040 mm (0.0006 to 0.0016 inch)
Maximum oil clearance: 0.06 mm (0.0024 inch)

NOTICE: Completely remove the Plastigage.





m. If the width is greater than maximum, select and replace the bearing. If necessary, use the undersize bearing.





HINT





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.
^ Keep the piston and connecting rod assemblies in the correct order so that they can be returned to the original locations when reassembling.

4. REMOVE CONNECTING ROD BEARING
a. Remove the connecting rod bearing from the connecting rod cap.
b. Remove the connecting rod bearing from the connecting rod.





5. REMOVE PISTON RING SET

HINT: Keep the piston rings in the correct combination and order so that they can be returned to the original locations when reassembling

a. Using a piston ring expander, remove the compression ring No. 1, No. 2 and oil ring.





6. REMOVE W/PIN PISTON SUB-ASSY
a. Using SST and a press, remove the piston pin.
SST 09221-25026 (09221-00021, 09221-00030, 09221-00061, 09221-00090, 09221-00100)

NOTICE: Do not change the combination of the piston and piston pin so that they can be returned to the original locations when reassembling.





7. INSPECT CRANKSHAFT THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance of the crankshaft while moving a screwdriver back and forth.
Standard thrust clearance: 0.09 to 0.19 mm (0.0035 to 0.0075 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than maximum, replace the thrust washer or crankshaft.

HINT: Thrust washer thickness is 2.43 to 2.48 mm (0.0957 to 0.0976 inch).





8. REMOVE CRANKSHAFT
a. Using SST, uniformly loosen the bearing caps in several steps in the sequence shown in the illustration.
SST 09011-38121
b. Remove the bearing caps and crankshaft.
9. REMOVE CRANKSHAFT THRUST WASHER UPPER
a. Remove the crankshaft thrust washer upper from the cylinder block.
10. REMOVE CRANKSHAFT BEARING
a. Remove the crankshaft bearing from the cylinder block.
b. Remove the crankshaft bearing from the bearing can.





11. REMOVE CYLINDER BLOCK WATER DRAIN COCK PLUG
a. Remove the cylinder block water drain cock plug from the cylinder block.





12. REMOVE OIL JET
a. Remove the oil jet from the cylinder block.





13. REMOVE STUD BOLT (FOR KNOCK SENSOR)
a. Remove the stud bolt (for knock control sensor) from the cylinder block.
14. REMOVE STUD BOLT





a. Remove the 6 stud bolts indicated in the illustration from the cylinder block.





15. REMOVE OIL PUMP SET RING PIN
a. Remove the 2 oil ring pins indicated in the illustration from the cylinder block





16. REMOVE CHAIN TENSIONER STRAIGHT PIN
a. Remove the chain tensioner straight pin indicated in the illustration from the cylinder block.





17. REMOVE CYLINDER HEAD SET STRAIGHT PIN
a. Remove the 2 cylinder straight pins indicated in the illustration from the cylinder block.





18. REMOVE OIL PAN STRAIGHT PIN
a. Remove the 2 oil pan straight pins indicated in the illustration from the cylinder block.





19. REMOVE END PLATE STRAIGHT PIN
a. Remove the 2 end plate straight pins indicated in the illustration from the cylinder block.





20. INSPECT CYLINDER BLOCK FOR FLATNESS
a. Using a precision straight edge and feeler gauge, measure the warpage on the top surface of the cylinder block.
Maximum warpage: 0.05 mm (0.0020 inch)
If the warpage is greater than maximum, replace the cylinder block.





21. INSPECT CYLINDER BORE
a. Using a cylinder gauge, measure the bore diameter at the 4 positions as illustrated.
b. Calculate the average of the thrust direction measurement and axial direction measurement at each level.
Standard diameter: 75.000 to 75.133 mm (2.9528 to 2.9580 inch)
If either of the 2 average values is greater than maximum, replace the cylinder block.
22. INSPECT CONNECTING ROD SUB-ASSY





a. Using a caliper gauge, measure the internal diameter of the connecting rod.
Connecting rod inside diameter: 17.965 to 17.985 mm (0.7073 to 0.7081 inch)
If the diameter is greater than maximum, replace the connecting rod.
b. Using a rod aligner and feeler gauge, check the connecting rod alignment.





1. Check the misalignment.
Maximum misalignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If the misalignment is greater than maximum, replace the connecting rod assembly.





2. Check the twist.
Maximum twist: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If the twist is greater than maximum, replace the connecting rod assembly.