EM 94

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ENGINE MECHANICAL (2UZ–FE) – CYL INDER BLOCK

(g) Install the connect ing rod cap w ith the 2 bolts (See page
EM 0) .
– 11
NOTICE:
Do not turn the crankshaft.
(h) Remove the 2 bolts , connect ing rod cap and lower bear“
ing (See procedure ( b) and (c) a bove) .

A05101

( i) Measure the Plast igage at its w idest po int .

Standard oil clearance:
0.027 – 0.053 mm (0.0011 – 0.0021 in.)
Maximum oil clearance: 0.065 mm (0.0026 in.)
If the o il clearance is greater than max imum , replace the bear“
ings . If necessary , replace the cran kshaft .

A05103

HINT:
If us ing a standard bear ing , replace it w ith one hav ing the same

num ber . If the num ber of the bear ing cannot be determined , se“
lect the correct bear ing by add ing together the num bers im“
Number
Mark pr inted on the connect ing rod cap and cran kshaft , then select“
ing the bear ing w ith the same num ber as the total . There are 6

No. 4 s izes of standard bear ings , mar ked 2 , 3 , 4 , 5 , 6 and 7 .

No. 3
No. 1 Number mark
No. 2 Connect ing rod cap 1 1 2 1 2 3 2 3 4 3 4 4
Crankshaft 1 2 1 3 2 1 3 2 1 3 2 3

Number Use bearing 2 3 4 5 6 7

Mark EXA MPLE:

Number Connect ing rod cap ”3” + Crankshaft ”1”

Mark = Tot al number 4 (Use bearing ”4 ”)
Reference
Connecting rod big end inside diameter:

Mark 1 55 .000 – 55 .006 mm (2 .1654 – 2 .1656 in .)

A05852
A05087 A05175 Mark 2 55 .006 – 55 .0 12 mm (2 .1656 – 2 .1658 in .)
A05853
Mark 3 55 .0 12 – 55 .0 18 mm (2 .1658 – 2 .166 1 in .)
Mark 4 55 .0 18 – 55 .024 mm (2 .166 1 – 2 .1663 in .)
Crankshaft crank pin diameter:

Mark 1 5 1.994 – 52 .000 mm (2 .0470 – 2 .0472 in .)

Mark 2 5 1.988 – 5 1.994 mm (2 .0468 – 2 .0470 in .)
Mark 3 5 1.982 – 5 1.988 mm (2 .0465 – 2 .0468 in .)
Standard sized bearing center w all thickness:

Mark 2 1.484 – 1.487 mm (0 .0584 – 0 .0585 in .)

Mark 3 1.487 – 1.490 mm (0 .0585 – 0 .0587 in .)

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ENGINE MECHANICAL (2UZ–FE) – CYL INDER BLOCK

Mark 4 1.490 – 1.493 mm (0 .0587 – 0 .0588 in .)

Mark 5 1.493 – 1.496 mm (0 .0588 – 0 .0589 in .)
Mark 6 1.496 – 1.499 mm (0 .0589 – 0 .0590 in .)
Mark 7 1.499 – 1.502 mm (0 .0590 – 0 .059 1 in .)
(j ) Completely remove the Plast igage .

20. RE MOV E PIS TO N A ND CONNE CT ING RO D A S×

SEMBLIES
(a) Us ing a r idge reamer, remove all the car bon from the top

of the cyl inder.

( b) Push the p iston , connect ing rod assem bly and upper
bear ing through the top of the cyl inder bloc k.
HINT:
Ridge eep the bear ings , connect ing rod and cap together.
Reamer Y K
rrange the p iston and connect ing rod assem bl ies in cor“
A04852 Y A
rect order.
21. CHECK CRA NKSHA FT THRUST CLEA RA NCE
Us ing a d ial ind icator, measure the thrust clearance wh ile pry ing
the cran kshaft bac k and forth w ith a screwdr iver.
Standard thrust clearance:
0.020 – 0.220 mm (0.0008 – 0.0087 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than max imum , replace the
thrust washers as a set .
Thrust w asher thickness:
A05096
2.440 – 2.490 mm (0.0961 – 0.0980 in.)
22. REMOV E MA IN BEA RING CA PS A ND CHECK OIL
3
7 CLEA RA NCE
(a) Un iformly loosen and remove the 0 ma in bear ing cap
5 9 1
1 4 bolts in several passes , in the sequence shown .
8
10
6
2

A05095

( b) Us ing 2 screwdr ivers , pry out the ma in bear ing cap , and
remove the 5 ma in bear ing caps , 5 lower bear ings and 2
lower thrust washers ( No . 3 ma in bear ing cap only) .
NOTICE:
Be careful not to damage the cylinder block.
HINT:
eep the lower bear ing and ma in bear ing cap together.
Y K
rrange the ma in bear ing caps and lower thrust washers
Y A
in correct order.
A05093
(c) Lift out the cran kshaft .
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EM 96
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ENGINE MECHANICAL (2UZ–FE) – CYL INDER BLOCK

HINT:
eep the upper bear ings and upper thrust washers together
K
w ith the cyl inder bloc k.
(d) Clean each ma in j ournal and bear ing .
(e) Chec k each ma in j ournal and bear ing for peel ings and

scratches .
If the j ournal or bear ing is damaged , replace the bear ings . If

necessary , replace the cran kshaft .

(f) Place the cran kshaft on the cyl inder bloc k.

Plast igage
(g) Lay a str ip of Plast igage across each j ournal .

A05097

(h) Install the ma in bear ing caps (See page EM 0) .

– 11
NOTICE:
Do not turn the crankshaft.
( i) Remove the ma in bear ing caps (See procedure (a) and
( b) a bove) .

A05095

(j ) Measure the Plast igage at its w idest po int .

Standard clearance:
No. 1, No. 5
0.028 – 0.046 mm (0.0011 – 0.0018 in.)
Others
0.040 – 0.058 mm (0.0016 – 0.0023 in.)
Maximum clearance: 0.070 mm (0.0028 in.)
If the o il clearance is greater than max imum , replace the bear“
ings . If necessary , replace the cran kshaft .
A05098

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 EM 97
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ENGINE MECHANICAL (2UZ–FE) – CYL INDER BLOCK

No. 4 No. 5 HINT:

No. 3
If us ing a standard bear ing , replace it w ith one hav ing the same
Number Mark
num ber . If the num ber of the bear ing cannot be determined , se“
No. 2 lect the correct bear ing by add ing together the num bers im“
pr inted on the cyl inder bloc k and cran kshaft , then refer to the
No. 1
Number ta ble below for the appropr iate bear ing num ber. There are 5
Mark s izes of the standard bear ings . For No .1 and No .5 pos it ion
bear ings , use bear ings mar ked 3 , 4 , 5 , 6 and 7 . For others pos i“
t ion bear ings , use bear ings mar ked , 2 , 3 , 4 and 5 .
1
No . 1 No . 5
,
Mark Use bearing
No. 5
No. 2 0– 5 3

No. 1 6 – 11 4
Cy linder block (A )
+ 12 – 17 5
No. 3 Crankshaft (B) 18 – 2 3 6
No. 4
24 – 2 8 7
Number EXA MPLE:
Cy linder block ”08” + Crankshaft ”06”
Mark
= Tot al number 14 (Use bearing ”5”)
A05089
A05088 A05176 Others
A05090
Mark Use bearing
0– 5 1

Cy linder block (A ) 6 – 11 2

+ 12 – 17 3
Crankshaft (B) 18 – 2 3 4
24 – 2 8 5
EXA MPLE:
Cy linder block ”08” + Crankshaft ”06”
= Tot al number 14 (Use bearing ”3”)
Reference
Cylinder block main j ournal bore diameter (A ):

Mark 00 72 .000 mm (2 .8346 in .)

Mark 0 1 72 .00 1 mm (2 .8347 in .)
Mark 02 72 .002 mm (2 .8347 in .)
Mark 03 72 .003 mm (2 .8348 in .)
Mark 04 72 .004 mm (2 .8348 in .)
Mark 05 72 .005 mm (2 .8348 in .)
Mark 06 72 .006 mm (2 .8349 in .)
Mark 07 72 .007 mm (2 .8349 in .)
Mark 08 72 .008 mm (2 .8350 in .)
Mark 09 72 .009 mm (2 .8350 in .)
Mark 10 72 .0 10 mm (2 .8350 in .)
Mark 11 72 .0 11 mm (2 .835 1 in .)
Mark 12 72 .0 12 mm (2 .835 1 in .)
Mark 13 72 .0 13 mm (2 .8352 in .)
Mark 14 72 .0 14 mm (2 .8352 in .)
Mark 15 72 .0 15 mm (2 .8352 in .)
Mark 16 72 .0 16 mm (2 .8353 in .)

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EM 98
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ENGINE MECHANICAL (2UZ–FE) – CYL INDER BLOCK

Crankshaft main j ournal diameter (B):

Mark 00 67 .000 mm (2 .6378 in .)

Mark 0 1 66 .999 mm (2 .6378 in .)
Mark 02 66 .998 mm (2 .6377 in .)
Mark 03 66 .997 mm (2 .6377 in .)
Mark 04 66 .996 mm (2 .6376 in .)
Mark 05 66 .995 mm (2 .6376 in .)
Mark 06 66 .994 mm (2 .6376 in .)
Mark 07 66 .993 mm (2 .6375 in .)
Mark 08 66 .992 mm (2 .6375 in .)
Mark 09 66 .99 1 mm (2 .6374 in .)
Mark 10 66 .990 mm (2 .6374 in .)
Mark 11 66 .989 mm (2 .6374 in .)
Mark 12 66 .988 mm (2 .6373 in .)
Standard bearing center w all thickness:
No. 1 and No. 5

Mark 3 2 .487 – 2 .490 mm (0 .0979 – 0 .0980 in .)

Mark 4 2 .490 – 2 .493 mm (0 .0980 – 0 .098 1 in .)
Mark 5 2 .493 – 2 .496 mm (0 .098 1 – 0 .0983 in .)
Mark 6 2 .496 – 2 .499 mm (0 .0983 – 0 .0984 in .)
Mark 7 2 .499 – 2 .502 mm (0 .0984 – 0 .0985 in .)
Others

Mark 1 2 .48 1 – 2 .484 mm (0 .0977 – 0 .0978 in .)

Mark 2 2 .484 – 2 .487 mm (0 .0978 – 0 .0979 in .)
Mark 3 2 .487 – 2 .490 mm (0 .0979 – 0 .0980 in .)
Mark 4 2 .490 – 2 .493 mm (0 .0980 – 0 .098 1 in .)
Mark 5 2 .493 – 2 .496 mm (0 .098 1 – 0 .0983 in .)
( k) Completely remove the Plast igage .
23. REMOV E CRA NKSHA FT
(a) Lift up the cran kshaft .
( b) Remove the 5 upper ma in bear ings and 2 upper thrust
washers from the cyl inder bloc k.
HINT:
rrange the ma in bear ing caps , bear ings and thrust washers in
A
correct order.

24. CHECK FIT BETW EEN PISTON A ND PISTON PIN

Try to move the p iston bac k and forth on the p iston p in .
If any movement is felt , replace the p iston and p in as a set .

A04862

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