TOYOTA CAMRY V20 1986 Service Information

INSPECTION OF PISTON AND
CONNECTING ROD ASSEMBLIES
1. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the piston top. 3. DISCONNECT CONNECTING ROD FROM PISTON
Using SST, press out the piston pin from the piston.
SST 09221±25024 (09221±00020, 09221±00030,
09221±00181, 09221±00190, 09221±00200)
HINT:
wThe piston and pin are a matched set.
wArrange the pistons, pins, rings, connecting rods and
bearings in correct order.
(c) Using solvent and a brush, thoroughly clean the piston.
NOTICE: Do not use a wire brush.
(b) Using a groove cleaning or broken ring, clean the pis-
ton ring grooves.
± ENGINE MECHANICALCylinder Block (2112±FE)EM±154

2. INSPECT PISTON DIAMETER AND OIL CLEARANCE
HINT: There are three sizes of the standard piston diameter,
marked º1 º, º2º and º3º accordingly. The marked is stamped
on the top of the piston.
(a) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 24.25 mm
(0.9547 in.) from the piston head.
Piston diameter:
STD mark 87.445 87.455 mm
(3.4427 ± 3.4431 in.)
STD mark º2º 87.455 87.465 mm
(3.4431 ± 3.. 5 in.)
STD mark º3º 87.465 ± 87.475 mm
(3.4435 ± 3.4439 in.)
O/S 0.50 87.945 ± 87.975 mm
(3.4624 ± 14636 in.)
(b) Measure the cylinder bore diameter in the thrust direc-
tions. (See step 5 on page EM±149)
(c) Subtract the piston diameter measurement from the
cylinder bore diameter measurement.
Standard oil clearance: 0.045 ± 0.065 mm
(0.0018 ± 0.0026 in.)
Maximum oil clearance: 0.085 mm (0.0033 in.)
If the oil clearance is greater than maximum, replace
all six pistons. If necessary, rebore all six cylinders or
replace the cylinder block.
HINT (Use cylinder block subassembly): when installing
a standard piston, install one with the same number
mark as the standard bore diameter marked on the cyl-
inder block.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±155

(c) Using a feeler gauge, measure the end gap.
Standard end gap:
No.1 0.300 0.520 mm
(0.0118 ± 0.0205 in.)
No.2 0.350 ± 0.600
(0.0138 0.0236 in.)
Oil (Slide rail) 0.200 0.550 mm
(0.0079 0.0217 in.)
Maximum end gap:
No.1 1.12 mm (0.0441 in.)
No.2 1.20 mm (0.0472 in.)
Oil (Slide rail) 1.15 mm (0.0453 in.)
If the end gap is greater than maximum, replace the pis-
ton ring. If the end gap is greater than maximum, even
with a new piston ring, rebore all six cylinders or replace
the cylinder block.3. INSPECT CLEARANCE BETWEEN WALL OF RING
GROOVE AND NEW PISTON RING
Using a feeler gauge, measure the clearance between new
piston ring and the wall of the piston ring groove.
Ring groove clearance:
No.1 0.010 ± 0.080 mm (0.0004 ± 0.0031 in.)
No.2 0.030 ± 0.070 mm (0.0012 ± 0.0028 in.)
If the clearance is greater than maximum, replace the piston.
5. INSPECT CONNECTING ROD
Using a rod aligner, check the connecting rod alignment.
wCheck for bending.
Maximum bending:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bent is greater than maximum, replace the connecting rod
assembly.4. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 100 mm (3.94 in.) from the top of the
cylinder block.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±156

(b) If the cap nut cannot be turned easily, measure the outer
diameter of the compressed thread with calipers.
Standard outer diameter: 7.860 ± 8.000 mm
(0.3094 ± 0.3150 in.)
Minimum outer diameter: 7.60 mm (0.2992 in.)
HINT: If the location of this area cannot be judged by
visual inspection, measure the outer diameter at the loca-
tion shown in the illustration.
If the outer diameter is less than minimum, replace the con-
necting rod bolt and cap nut as a set.wCheck for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3±94 in.)
If twist is greater than maximum, replace the connecting
rod assembly.
6. INSPECT CONNECTING ROD BOLTS
(a) Install the cap nut to the connecting rod bolt. Check that the
cap nut can be turned easily by hand to the end of the
thread.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±157

BORING OF CYLINDERS
HINT:
wBore all the six cylinders for the oversized piston outside di-
ameter.
wReplace the piston rings with ones to match the oversized
pistons.
1. KEEP OVERSIZED PISTONS
Oversized piston diameter:
O/S 0.50 87.945 ± 87.975 mm
(3.4624 ± 3.4636 in.)
2. CALCULATE AMOUNT TO BORE CYLINDER
(a) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 24.25 mm
(0.9547 in.) from the piston head.
(b) Calculate the amount each cylinder is to be rebored as fol-
lows:
Size to be .rebored = P + C ± H
P= Piston diameter
C = Piston oil clearance
0.045 ± 0.065 mm (0.0018 ± 0.0026 in.)
H = Allowance for honing
0.02 mm (0.0008 in.) or less
3. BORE AND HONE CYLINDERS TO CALCULATED
DIMENSIONS
Maximum honing: 0.02 mm (0.0008 in.)
NOTICE: Excess honing will destroy the finished round-
ness.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±158

2. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
STD 63.985 ± 64.000 mm
(2.5191 ± 2.5197 in.)
U/S 0.25 63.745 ± 63.755 mm
(2.5096 ± 2.5100 in.)
Crank pin diameter:
STD 47.987 ± 48.000 mm .
(1.8892 ± 1.8898 in.)
U/S 0.25 47.745 ± 47.755 mm
(1.8797 ± 1.8801 in.)
If the diameter is not as specified, check the oil clearance
(See pages EM±147 to 150).
(b) Check each main journal and crank pin for taper and out±of±
round as shown.
Maximum taper and out±of±round: 0.42 mm
(0.0008 in.)
If the taper or out±of±round is greater than maximum,
grind or replace the crankshaft.
3. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the
finished undersized diameter (See procedure step 2).
Install new main journal and/or crank pin undersized bear-
ings.
INSPECTION AND REPAIR OF
CRANKSHAFT
1. INSPECT CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V±blocks.
(b) Using a dial indicator, measure the circle runout at the cen-
ter journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the
crankshaft.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±159

B. If oil pump is installed to the cylinder block:
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE: Be careful not to damage the crankshaft.
Tape the screwdriver tip.
(b) Using SST and a hammer, tap in a new oil seal until its
surface is flush with the oil pump case edge.
SST 09309±37010
(c) Apply MP grease to the oil seal lip.
(c) Apply IMP grease to a new oil seal lip.
(d) Using SST and a hammer, tap in the oil seal until its sur-
face is flush with the oil pump case edge.
SST 09309±37010 1. REPLACE CRANKSHAFT FRONT OIL SEAL
A. If Oil Pump 1s removed from cylinder block:
(a) Using a screwdriver and hammer, tap out the oil seal.
REPLACEMENT OF CRANKSHAFT OIL
SEALS
HINT: There are two methods (A an B) to replace the oil
seal as follows:
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±160

6. If rear oil seal retainer is installed to cylinder block:
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE: Be careful not to damage the crankshaft.
Tape the screwdriver tip.
2. REPLACE CRANKSHAFT REAR OIL SEAL
A. If rear oil seal retainer is removed from cylinder block:
(a) Using a screwdriver and hammer, tap out the oil seal.
(b) Using SST and a hammer, tap in a new oil seal until its
surface is flush with the rear oil seal edge.
SST 09223±56010
(c) Apply MP grease to the oil seal lip.
(c) Apply MP grease to a new oil seal lip.
(d) Using SST and a hammer, tap in the oil seal until its sur-
face is flush with the rear oil seal retainer edge.
SST 09223±56010
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±161

ASSEMBLY OF PISTON AND CONNECTING
ROD ASSEMBLIES
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Align the front marks of the piston and connecting rod.
Connecting rod front (mold) mark:
B6, 1 B, 8A, C3 or etc.
(b) Coat the piston pin and piston hole of the piston with
engine oil. .
(c) Using SST, press in the piston pin.
SST 09221±25024 (09221±00020, 09221±00030,
09221±00181, 09221±00190, 09221±00200)
(d) Check that the piston smoothly moves back and forth
on the piston pin.
(b) Using a piston ring expander, install the two com-
pression rings with the code mark facing upward.
Code mark: No.1 T or 1R
No.2 T2 or 2R 2. INSTALL PISTON RINGS
(a) Install the oil ring expander and two side rails by hand.
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE: Do not align the ring ends.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±162

1. INSTALL MAIN BEARINGS
HINT:
wMain bearings come in widths of 20 mm (0.79 in.) and
22 mm (0.87 in.). Install the 22 mm (0.87 in.) bearings in the
No. 1 cylinder block journal position with the main bearing
caps. Install the 20 mm (0.79 in.) bearings in the other posi-
tions.
wUpper bearings have on oil groove and oil holes; lower bear-
ings do not.
(a) Align the bearing claw with the claw groove of the main bear-
ing cap or cylinder block.
(b) Install the bearings in the cylinder block and main bearing
cap.
NOTICE: Install the bearing with the oil hole in the cylinder
block.
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the con±
necting rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting rod
cap.
NOTICE: Install the bearing with the oil hole in the connect-
ing rod.
ASSEMBLY OF CYLINDER BLOCK
(See page EM±139)
HINT:
wThoroughly clean all parts to be assembled.
wBefore installing the parts, apply new engine oil to all
sliding and rotating surfaces.
wReplace all gaskets. 0±rings and oil seals with new parts.
2. INSTALL UPPER THRUST WASHERS
Install the thrust washers under the No.2 journal position of
the block with the oil grooves facing outward.
3. PLACE CRANKSHAFT ON CYLINDER BLOCK
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±163