TOYOTA CAMRY 1999 Service Repair Manual

S05569A07350A07397
Mark 1, 2 or 3Mark 1, 2 or 3
No.1No.2 No.3No.4
A07348
A01916
110 mm
EM7639
EM±100
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1272 Author: Date:
HINT:
Use new cylinder block:
Use a piston with the same number mark as the cylinder bore
diameter marked on the cylinder block.
(b) Inspect the piston ring groove clearance.
Using a feeler gauge, measure the clearance between
new piston ring and the wall of the ring groove.
Ring groove clearance (No.1, No.2):
0.030 ± 0.070 mm (0.0012 ± 0.0028 in.)
If the clearance is not as specified, replace the piston.
(c) Inspect the piston ring end gap.
(1) Insert the piston ring into the cylinder bore.
(2) Using a piston, push the piston ring a little beyond
the bottom of the ring travel, 110 mm (4.33 in.) from
the top of the cylinder block.
(3) Using a feeler gauge, measure the end gap.
Standard end gap:
No.10.270 ± 0.490 mm (0.0106 ± 0.0192 in.)
No.20.450 ± 0.670 mm (0.0177 ± 0.0263 in.)
Oil (Side rail)0.100 ± 0.470 mm (0.0039 ± 0.0185 in.)
Maximum end gap:
No.11.09 mm (0.0429 in.)
No.21.27 mm (0.0499 in.)
Oil (Side rail)1.07 mm (0.0421 in.)

A06594
Z00064
Z00065
EM7538
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±101
1273 Author: Date:
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, rebore all the 4 cylinders (see page EM±104) or replace
the cylinder block.
(d) Inspect the piston pin fit.
At 60°C (140°F), you should be able to push the piston
pin into the piston pin hole with your thumb.
(e) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bend is greater than maximum, replace the connecting rod as-
sembly.
(2) Check 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 as-
sembly.
(f) Inspect the piston pin oil clearance.
(1) Using a caliper gauge, measure the inside diameter
of the connecting rod bushing.
Bushing inside diameter:
22.005 ± 22.017 mm (0.8663 ± 0.8668 in.)

EM0227
P13428
A02826
15 mm
(0.59 in.)
EM±102
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1274 Author: Date:
(2) Using a micrometer, measure the piston pin diame-
ter.
Piston pin diameter:
21.997 ± 22.009 mm (0.8660 ± 0.8665 in.)
(3) Subtract the piston pin diameter measurement from
the bushing inside diameter measurement.
Standard oil clearance:
0.005 ± 0.011 mm (0.0002 ± 0.0004 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, replace the bush-
ing. (See page EM±104) If necessary, replace the piston and
piston pin as a set.
(g) Inspect the connecting rod bolts.
(1) 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.
(2) If the cap nut cannot be turned easily, measure the
outside diameter of the connecting rod bolt with a
vernier caliper.
Standard diameter:
7.860 ± 8.000 mm (0.3094 ± 0.3150 in.)
Minimum 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 location shown in the illustra-
tion.
If the outside diameter is less than minimum, replace the con-
necting rod bolt and nut as a set.

P00118
EM3553
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±103
1275 Author: Date:
5. INSPECT CRANKSHAFT
(a) Inspect for circle runout.
(1) Place the crankshaft on V±blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
(b) Inspect the main journals and crank pins.
(1) Using a micrometer, measure the diameter of each
main journal and crank pin.
Main journal diameter:
STD54.988 ± 55.003 mm (2.1653 ± 2.1655 in.)
U/S 0.2554.745 ± 54.755 mm (2.1553 ± 2.1557 in.)
Crank pin diameter:
STD51.985 ± 52.000 mm (2.0466 ± 2.0472 in.)
U/S 0.2551.745 ± 51.755 mm (2.0372 ± 2.0376 in.)
If the diameter is not as specified, check the oil clearance. (See
page EM±86) If necessary, grind or replace the crankshaft.
(2) Check each main journal and crank pin for taper
and out±of±round as shown.
Maximum taper and out±of±round:
0.02 mm (0.0008 in.)
If the taper and out±of±round is greater than maximum, replace
the crankshaft.
6. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the fin-
ished undersized diameter. (See procedure in step 5) Install
new main journal and/or crankshaft pin undersized bearings.

EM08K±03
EM1321
SST
EM7329
Oil Hole
P01038
EM1322
EM±104
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1276 Author: Date:
REPLACEMENT
1. REPLACE CONNECTING ROD BUSHINGS
(a) Using SST and a press, press out the bushing.
SST 09222±30010
(b) Align the oil holes of a new bushing and the connecting
rod.
(c) Using SST and a press, press in the bushing.
SST 09222±30010
(d) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance (See page EM±97) be-
tween the bushing and piston pin.
(e) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.
2. REPLACE OVERSIZED (O/S) PISTONS FOR CYLIN-
DER BORING
HINT:

Bore all the 4 cylinders for the O/S piston outside diame-
ter.

Replace all the piston rings with ones to match the O/S
pistons.
(a) Keep 4 new O/S pistons.
O/S 0.50 piston diameter:
87.350 ± 87.380 mm (3.4390 ± 3.4402 in.)

A07352
20.5 mm
S01546
SST
S05573
Cut Position
Pry
S05572
SST
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±105
1277 Author: Date:
(b) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 20.5 mm (0.807 in.)
from the piston head.
(c) Calculate the amount of each cylinder is to be rebored as
follows:
Size to be rebored = P + C ± H
P = Piston diameter
C = Piston oil clearance
0.175 ± 0.195 mm (0.0068 ± 0.0076 in.)
H = Allowance for honing
0.02 mm (0.0008 in.) or less
(d) Bore and hone the cylinders to calculated dimensions.
Maximum honing: 0.02 mm (0.0008 in.)
NOTICE:
Excess honing will destroy the finished roundness.
3. REPLACE CRANKSHAFT FRONT OIL SEAL
HINT:
There are 2 methods ((a) and (b)) to replace the oil seal.
(a) If the oil pump is removed from the cylinder block:
(1) Using a screwdriver and hammer, tap out the oil
seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the oil pump body edge.
SST 09226±10010
(3) Apply MP grease to the oil seal lip.
(b) If the oil pump is installed to the cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the oil pump body edge.
SST 09226±10010

EM7362
P19502
SST
S06005
Cut position
S06004
SST EM±106
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1278 Author: Date:
4. REPLACE CRANKSHAFT REAR OIL SEAL
HINT:
there are 2 methods ((a) and (b)) to replace the oil seal.
(a) If the rear oil seal retainer is removed from the cylinder
block:
(1) Using a screwdriver and hammer, tap out the oil
seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the rear oil seal retainer
edge.
SST 09223±15030, 09950±70010 (09951±07100)
(3) Apply MP grease to the oil seal lip.
(b) If rear oil seal retainer is installed to cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)

EM08L±03
A06586
A01776
A07349
Front Mark
(Cavity)
Front Mark
(Protrusion)
A06587
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±107
1279 Author: Date:
REASSEMBLY
HINT:

Thoroughly clean all parts to be assembled.

Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.

Replace all gaskets, O±rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Using a small screwdriver, install a new snap ring on one
side of the piston pin hole.
(b) Gradually heat the piston to 80 ± 90°C (176 ± 194°F).
(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting rod,
and push in the piston pin with your thumb.
(e) Using a small screwdriver, install a new snap ring on the
other side of the piston pin hole.

A06588
No.1
No.2Code Mark
Code Mark
A07351
Upper Side Rail
ExpanderFront
Mark
(Cavity) No.1
Compression
Ring
No.2
Compression
RingLower Side Rail
P
P00797
P05533
22.9 mm
19.2 mm Others
No.3
P05353
EM±108
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1280 Author: Date:
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the No.2 and No.1
piston rings with the code mark facing upward.
Code mark:
No.11N or T
No.22N or 2T
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the ring ends.
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
4. INSTALL MAIN BEARINGS
HINT:

Main bearings come in widths of 19.2 mm (0.756 in.) and
22.9 mm (0.902 in.). Install the 22.9 mm (0.902 in.) bear-
ings in the No.3 cylinder block journal position with the
main bearing cap. Install the 19.2 mm (0.756 in.) bearings
in the other positions.

Upper bearings have an oil groove and oil holes; lower
bearings do not.
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 5 upper bearings.

P03177
Mark
1, 2, 3, 4, or 5
P05354
P03173
S06012
P00104
1
10
735
84269
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±109
1281 Author: Date:
(b) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 5 lower bearings.
HINT:
A number is marked on each main bearing cap to indicate the
installation position.
5. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No.3 journal position of
the cylinder block with the oil grooves facing outward.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK
7. INSTALL MAIN BEARING CAPS AND LOWER
THRUST WASHERS
(a) Install the 2 thrust washers on the No.3 bearing cap with
the grooves facing outward.
(b) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and front mark.
(c) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(d) Install and uniformly tighten the 10 bolts of the main bear-
ing cap in several passes, in the sequence shown.
Torque: 59 N´m (600 kgf´cm, 43 ft´lbf)
(e) Check that the crankshaft turns smoothly.
8. CHECK CRANKSHAFT THRUST CLEARANCE
(See page EM±86)