2AR-FE ENGINE MECHANICAL  CYLINDER BLOCK  DISASSEMBLY  

Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

Standard thrust clearance:

0.160 to 0.512 mm (0.00630 to 0.0202 in.)

Maximum thrust clearance:

0.512 mm (0.0202 in.)

If the thrust clearance is more than the maximum, replace the connecting rod. If necessary, replace the crankshaft.

1.385,0.146 1.302,0.146 false 1.302,0.146 0.698,0.813 false 1.417,0.063 1.573,0.229 0.156,0.167 10 *1

*1	Alignment Mark

Check the alignment marks on the connecting rod and cap to ensure correct reassembly.

Remove the 2 bolts and connecting rod cap.

HINT:

Keep the lower bearing and connecting rod cap together.

2.875,1.875 2.792,1.875 false 2.792,1.875 1.5,1.24 false 2.875,1.875 2.792,1.875 false 2.792,1.875 1.5,1.24 false 2.917,1.771 3.094,1.927 0.177,0.156 10 *1

*1	Plastigage

Lay a strip of Plastigage on the crank pin.

0.906,0.052 1.021,0.052 false 1.021,0.052 1.344,0.688 false 1.188,2.76 1.292,2.76 1.292,2.76 1.667,3.042 false 1.656,3.313 1.271,2.76 false 1.135,3.74 1.229,3.75 1.229,3.75 1.417,4.031 false 0.677,0 0.865,0.313 0.188,0.313 10 *1 0.917,2.677 1.104,3 0.188,0.323 10 *2 0.917,3.677 1.104,4 0.188,0.323 10 *2

*1	Plastigage
*2	Number Mark

Measure the Plastigage at its widest point.

Standard oil clearance:

0.030 to 0.063 mm (0.00118 to 0.00248 in.)

Maximum oil clearance:

0.07 mm (0.00276 in.)

NOTICE:

Remove the Plastigage completely after the measurement.

If the oil clearance is more than the maximum, replace the connecting rod bearing. If necessary, grind or replace the crankshaft.

HINT:

If replacing a bearing, select a new one with the same number as that which is marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.

Standard crank pin diameter:

51.492 to 51.500 mm (2.0272 to 2.0276 in.)

Standard Connecting Rod Big End Inside Diameter:

Item	Specified Condition
Mark 1	54.500 to 54.508 mm (2.1457 to 2.1460 in.)
Mark 2	54.509 to 54.516 mm (2.1460 to 2.1463 in.)
Mark 3	54.517 to 54.524 mm (2.1463 to 2.1466 in.)

Standard Size Bearing Center Wall Thickness:

Item	Specified Condition
Mark 1	1.486 to 1.490 mm (0.05850 to 0.05866 in.)
Mark 2	1.491 to 1.494 mm (0.05870 to 0.05882 in.)
Mark 3	1.495 to 1.498 mm (0.05886 to 0.05898 in.)

Using a ridge reamer, remove all the carbon from the top of the cylinder.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

Standard thrust clearance:

0.04 to 0.24 mm (0.00157 to 0.00945 in.)

Maximum thrust clearance:

0.30 mm (0.0118 in.)

If the thrust clearance is more than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.

Standard thrust washer thickness:

1.93 to 1.98 mm (0.0760 to 0.0780 in.)

3.115,1.542 3.271,1.74 0.156,0.198 10 1 3.104,0.521 3.26,0.719 0.156,0.198 10 2 0.375,1.542 0.531,1.74 0.156,0.198 10 3 0.375,0.542 0.531,0.74 0.156,0.198 10 4 2.448,1.625 2.604,1.823 0.156,0.198 10 5 2.448,0.469 2.604,0.667 0.156,0.198 10 6 1.021,1.583 1.177,1.781 0.156,0.198 10 7 1,0.469 1.156,0.667 0.156,0.198 10 8 1.75,1.667 1.906,1.865 0.156,0.198 10 9 1.708,0.438 1.969,0.635 0.26,0.198 10 10

Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

Remove the thrust washers from the cylinder block.

0.979,1.755 1.161,1.915 0.182,0.161 10 *1 1.057,1.745 1.057,1.642 false 1.057,1.642 1.35,1.309 false

*1	Piston Ring Expander

Using a piston ring expander, remove the 2 compression rings.

Insert a small screwdriver into the service hole and pry out the snap ring on the front side.

NOTICE:

Do not remove the snap ring on the rear side unless it is necessary. When the snap ring heeds to be removed, be careful not to damage the piston.

Using a plastic-faced hammer and brass bar, lightly tap out the piston pin. Then remove the connecting rod.

HINT:

·

The piston and pin are a matched set.

·

Be sure to arrange the removed pistons, pins, rings, connecting rods and bearings in such a way that the parts can be reinstalled exactly as before.

·

Arrange the pistons, piston pins, rings, connecting rods and bearings in the correct order.

Using a 5 mm hexagon wrench, remove the 2 bolts and 2 No. 1 oil nozzle sub-assemblies.

Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 2 oil nozzle sub-assemblies.