Part 2

1NZ-FXE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

DISASSEMBLY (Continued)

34. 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:
0.16 to 0.36 mm (0.0063 to 0.0142 in.)
Maximum thrust clearance:
0.36 mm (0.0142 in.)
If the thrust clearance is greater than the maximum, replace the connecting rod.
35. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly.

(b) Using SST, remove the 2 connecting rod cap bolts.
SST: 09205-16010
(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.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scratches.

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

(g) Match together the connecting rod and cap in the correct combination. Then install the cap onto the connecting rod, making sure that the front mark on the cap is correctly oriented.
(h) Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

(i) Using SST, tighten the bolts in several steps by the specified torque.
SST: 09205-16010
Torque: 15 Nm (153 kgf-cm, 11 ft-lbf)
NOTE: Do not turn the crankshaft.

(j) Mark the front of the connecting cap bolts with paint.
(k) Retighten the cap bolts by 90° as shown in the illustration.
NOTE: Do not turn the crankshaft.

(l) Remove the 2 bolts, connecting rod cap and lower bearing.

(m) Measure the Plastigage at its widest point.
Standard oil clearance:
0.016 to 0.040 mm (0.0006 to 0.0016 in.)
Maximum oil clearance:
0.06 mm (0.0024 in.)
NOTE: Completely remove the Plastigage.

(n) If the oil clearance is greater than the maximum, select and replace the bearing. If necessary, use an undersized bearing.
Reference:

36. REMOVE PISTON WITH CONNECTING ROD

(a) Using a ridge reamer, remove all 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 the connecting rod assemblies in the correct order so that they can be returned to their original locations when re-assembling.

37. REMOVE CONNECTING ROD BEARING
38. 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:
0.09 to 0.19 mm (0.0035 to 0.0075 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Check the crankshaft and block for wear. Repair or replace if necessary.
HINT: Thrust washer thickness: 2.43 to 2.48 mm (0.0957 to 0.0976 in.)

39. REMOVE CRANKSHAFT AND INSPECT OIL CLEARANCE

(a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts with SST in the sequence shown in the illustration.
SST: 09011-38121
(b) Remove the 5 bearing caps and crankshaft.
(c) Clean each main journal and bearing.

(d) Install the upper bearing with the oil groove onto the cylinder block, and the lower bearing onto the bearing cap.
NOTE: Do not apply engine oil to the contact surfaces of the cylinder block or the backside of the bearing.
HINT: The mass production parts do not have claws as marks. If reusing the mass production parts, measure the clearance of both sides with the bearing in the center of the bearing cap.

Standard clearance:
A - B = within 0.8 mm (0.032 in.)
(e) Install the crankshaft onto the cylinder block.

(f) Lay a strip of Plastigage across each journal.

(g) Check the front marks and numbers and install the bearing caps onto the cylinder block.
(h) Apply a light coat of engine oil to the threads of the bearing cap bolts.

(i) Using SST, tighten the bolts in several steps by the specified torque in the sequence shown in the illustration.
SST: 09011-38121
Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)
NOTE: Do not turn the crankshaft.

(j) Mark the front of the bearing cap bolts with paint.
(k) Retighten the bearing cap bolts by 90° in the same sequence.
(l) Check that the painted mark is now at a 90° angle to the front.
NOTE: Do not turn the crankshaft.

(m) Remove the bearing cap.
(n) Measure the Plastigage at its widest point.

Standard oil clearance:
0.010 to 0.023 mm (0.0004 to 0.0009 in.)
Maximum oil clearance:
0.07 mm (0.0028 in.)
NOTE: Completely remove the Plastigage.
HINT:
- If the oil clearance is greater than the maximum, select and replace the bearing. If necessary, use an undersized bearing.

- To select the correct bearing size, calculate the bearing number by adding together the numbers imprinted on the cylinder block and crank journal.
Example:
Imprinted number on the cylinder block is 3. Imprinted number on the crank journal is 5. 3 + 5 = 8 Select the bearing with the bearing number 3.
Standard cylinder block diameter:

Standard crankshaft journal diameter:

Reference:

40. REMOVE CRANKSHAFT BEARING
41. REMOVE CRANKSHAFT THRUST WASHER
42. REMOVE PISTON RING SET
HINT: Keep the piston rings in the correct combination and correct order so that they can be returned to their original locations when reassembling.

(a) Using a piston ring expander, remove the 2 compression rings.
(b) Remove the oil ring (side rail and expander) by hand.
43. REMOVE PISTON PIN

(a) Using SST, press out the piston pin from the piston.
SST: 09221-25026
09221-00021
09221-00030
09221-00190
09221-00141
09221-00150
NOTE: Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they can be returned to their original locations when reassembling.

44. REMOVE CYLINDER BLOCK WATER DRAIN COCK

(a) Remove the cylinder block water drain cock from the cylinder block.
45. REMOVE OIL JET

(a) Remove the oil jet from the cylinder block.
46. REMOVE STUD BOLT

(a) Remove the stud bolt for the knock control sensor from the cylinder block.
(b) Using an E5 "TORX" socket, remove the 6 stud bolts from the cylinder block.

47. REMOVE RING PIN

(a) Remove the 2 oil pump ring pins from the cylinder block.
48. REMOVE STRAIGHT PIN

(a) Remove the chain tensioner straight pin from the cylinder block.

(b) Remove the 2 cylinder head straight pins from the cylinder block.

(d) Remove the 2 end plate straight pins from the cylinder block.
49. REMOVE TIGHT PLUG