Disassembly Of Cylinder Block

(See page EM-133)

1. REMOVE REAR OIL SEAL RETAINER

Remove the six bolts, retainer and gasket.

Tercel Oil Seal

CHECK 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 - 0.312 mm

Maximum thrust clearance: 0.35 mm (0.0138 in.)

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

REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE

(a) Using a punch or numbering stamp, place the matchmarks on the connecting rod and cap to ensure correct reassembly.

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(b) Remove the connecting rod cap nuts.

(c) Using a plastic-faced hammer, lightly tap the connecting rod bolts and lift off the connecting rod cap.

HINT: Keep the lower bearing inserted with the connecting cap.

(d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.

(e) Clean crank pin and bearing.

(f) Check the crank pin and bearing for pitting and scratches.

If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.

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

Plastigage

(h) Install the connecting rod cap. (See step 7 on page EM-166)

NOTICE: Do not turn the crankshaft.

(i) Remove the connecting rod cap. (See procedures (b) and (c) above)

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(j) Measure the Plastigage at its widest point

Standard oil clearance: STD

0.024 - 0.055 mm (0.0009 - 0.0022 in.) 0.023 - 0.069 mm (0.0009 - 0.0027 in.)

If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.

Maximum oil clearance:

Mark

f

1, 2 or 3

Mark

1, 2 or 3

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HINT: If using a standard bearing, replace it with one having the same number marked on the connecting rod cap. There are three sizes of standard bearings, marked "1", "2" and "3" accordingly.

Standard sized bearing center wall thickness:

Mark '1" 1.484 - 1.488 mm (0.0584 - 0.0586 in.) Mark "2" 1.488 - 1.492 mm (0.0586 - 0.0587 in.) Mark "3" 1.492 - 1.496 mm (0.0587 - 0.0589 in.)

(k) Completely remove the Plastigage.

4. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES

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

(b) Cover the connecting rod bolts. (See page EM-146)

(c) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

HINT:

• Keep the bearings, connecting rod and cap together.

• Arrange the piston and connecting rod assemblies in correct order.

Crankshaft Arrange Cylinder Block

5. CHECK CRANKSHAFT THRUST CLEARANCE

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

Standard thrust clearance: 0.020 - 0.220 mm

Maximum thrust clearance: 0.30 mm (0.0118 in.

If the thrust clearance is greater than maximum, replace the thrust washers as a set.

Thrust washer thickness: 2.440 - 2.490 mm

6. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE

(a) Remove the main bearing cap bolts.

(b) Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the main bearing caps, lower bearings and lower thrust washers (No.3 main bearing cap only).

HINT:

• Keep the lower bearing and main bearing cap together.

• Arrange the main bearing caps and lower thrust washers in correct order.

(c) Lift out the crankshaft.

HINT: Keep the upper bearing and upper thrust washers together with the cylinder block.

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(d) Clean each main journal and bearing.

(e) Check each main journal and bearing for pitting and scratches.

If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.

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(h) Install the main bearing caps. (See step 5 on page EM-165)

NOTICE: Do not turn the crankshaft.

No.4

No.4

No.5

No.5

_Mark

_Mark

(i) Remove the main bearing caps. (See procedures (a) and (b)above)

(j) Measure the Plastigage at its widest point. Standard clearance:

No.3

Others STD

Maximum clearance:

0.025 - 0.044 mm (0.0010 - 0.0017 in.) 0.021 - 0.061 mm (0.0008 - 0.0024 in.) 0.015 - 0.034 mm (0.0006-0.0013 in.) 0.029 - 0.069 mm (0.0011 -0.0027 in.)

HINT: If replacing the cylinder block subassembly, the bearing standard clearance will be:

0.027 - 0.054 mm (0.0011 -0.0021 in.) 0.017 - 0.044 mm (0.0007-0.0017 in.)

If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.

HINT: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then select the bearing with the same number as the total. There are five sizes of standard bearings, marked "1," "2," "3," "4" and "5" accordingly.

No.3 Others

Number marked

Cylinder block

1

2

3

Crankshaft

0

1

2

0

1

2

0

1

2

Bearing

1

2

3

1

2

3

1

2

3

EXAMPLE: Cylinder block "2" + Crankshaft "1" = Bearing "3"

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Cylinder block main journal bore diameter:

Mark "1 " 59.020 - 59.026 mm (2.3236 - 2.3239 in

Mark "2" 59.026 - 59.032 mm (2.3239 - 2.3241 in.

Mark "3" 59.032 - 59.038 mm (2.3241 - 2.3243 in

Crankshaft journal diameter:

Mark "0" 54.998 - 55.003 mm (2.1653-2.1655 in.)

Mark "1 " 54.993 - 54.998 mm (2.1651 -2.1653 in.

Mark "2" 54.988 - 54.993 mm (2.1649-2.1651 in.)

Standard sized bearing center wall thickness: No.3 Mark "1 " 1.992 - 1.995 mm (0.0784 - 0.0785 in.

Mark "2" 1.995 - 1.998 mm (0.0785 - 0.0787 in.

Mark "3" 1.998 - 2.001 mm (0.0787 - 0.0788 in.

Mark "4" 2.001 - 2.004 mm (0.0788-0.0789 in.

Mark "5" 2.004 - 2.007 mm (0.0789 - 0.0790 in. Others Mark "1 " 1.997 - 2.000 mm (0.0786 - 0.0787 in.

Mark "2" 2.000 - 2.003 mm (0.0787 - 0.0789 in.

Mark "3" 2.003 - 2.006 mm (0.0789 - 0.0790 in.

Mark "4" 2.006 - 2.009 mm (0.0790-0.0791 in.

Mark "5" 2.009 - 2.012 mm (0.0791 - 0.0792 in.

(k) Completely remove the Plastigage.

REMOVE CRANKSHAFT

(a) Lift out the crankshaft.

(b) Remove the upper bearings and upper thrust washers from the cylinder block.

Upper

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