Engine Repair Manual

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  • Topic: Engine technology, Camshaft, Poppet valve
  • Pages : 133 (22883 words )
  • Download(s) : 221
  • Published : October 28, 2011
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16–1
COOLING – WATER PUMP ASSY (1ZZ–FE/3ZZ–FE)

WATER PUMP ASSY (1ZZ–FE/3ZZ–FE)
160AO–01

INSPECTION
1. (a) INSPECT WATER PUMP ASSY Visually check the drain hole for coolant leakage.

Hole

B10233

1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E)

14–38
ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE)

CYLINDER BLOCK (1ZZ–FE/3ZZ–FE)
140KO–01

COMPONENTS
Compression Ring No.1 Compression Ring No.2 Oil Ring (Side Rail) Oil Ring (Expander) Piston z Snap Ring z Bush z Snap Ring Piston Pin Connecting Rod

Connecting Rod Bearing

5.0 (51, 44 in.Vlbf)

Ring Pin Straight Pin Straight Pin Cylinder Block Sub–assy

11 (112, 8)

Ring Pin Crankshaft Bearing Crankshaft Thrust Washer Upper Key Crankshaft Connecting Rod Bearing See page 14–39 1st 20 (204, 15) 2nd Turn 90_

5.0 (51, 44 in.Vlbf)

Straight Pin Crankshaft Thrust Washer Upper

Crankshaft Bearing Connecting Rod Bearing Cap Crankshaft Bearing Cap Sub–assy

Straight Pin Ring Pin
5.0 (51, 44 in.Vlbf) 19 (194, 14) See page 14–39 1st 44 (449, 33) 2nd Turn 90_ 5.0 (51, 44 in.Vlbf) A62767

N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part

1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E)

14–39
ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE)
140KP–01

OVERHAUL

1. (a)

INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.160 – 0.342 mm (0.063 – 0.0135 in.) Maximum thrust clearance: 0.342 mm (0.0135 in.)

A01155

2.

A01156

INSPECT CONNECTING ROD BEARING OIL CLEARANCE NOTICE: Do not turn the crankshaft. (a) Using marking paint, write the matched cylinder number on each connecting rod and cap. HINT: The match marks on the connecting rods and caps are for ensuring correct reassembly. (b) Using SST, remove the 2 connecting rod cap bolts. SST 09205–16010 (c) Clean the crank pin and bearing. (d) Check the crank pin and bearing for pitting and scratches.

Plastigage

(e)

Lay a strip of Plastigage across the crank pin.

A01159

(f)
Front

Check that the protrusion of the connecting rod cap is facing in the correct direction.

A62797

1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E)

14–40
ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE)

(g) (h)

Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. Using SST, tighten the bolts in several passes by the specified torque. SST 09205–16010 Torque: 20 NVm (204 kgfVcm, 15 ftVlbf)

A01163

90_ Front

Paint Mark

(i) (j) (k) (l)

Mark the front of the connecting cap bolts with paint. Retighten the cap bolts by 90_ as shown in the illustration. Check that the crankshaft turns smoothly. Remove the 2 bolts, connecting rod cap and lower bearing.

A62798

(m)

Measure the Plastigage at its widest point. Standard oil clearance: 0.028 – 0.060 mm (0.0011 – 0.0024 in.) Maximum oil clearance: 0.080 mm (0.0031 in.) NOTICE: Remove the Plastigage completely after the measurement.

A01160

(n)

Mark 1, 2 or 3

If replacing a bearing, select a new one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked ”1”, ”2” and ”3” accordingly. Reference: Standard bearing center wall thickness Mark 1 2 3 mm (in.) 1.486 – 1.490 (0.0585 – 0.0587) 1.490 – 1.494 (0.0587 – 0.0588) 1.494 – 1.498 (0.0588 – 0.0590)

A62799

3. (a) (b) HINT:
S S
A01166

REMOVE PISTON SUB–ASSY W/CONNECTING ROD Using a ride reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.

1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL (RM923E)

14–41
ENGINE MECHANICAL – CYLINDER BLOCK (1ZZ–FE/3ZZ–FE)

4. (a)

REMOVE CONNECTING ROD BEARING Remove the connecting...
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