TOYOTA CAMRY 2000 Service Repair Manual

8. 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 (0.0008 ± 0.0087 in.)
Maximum thrust clearance:
0.30 mm l0.0118 in.)
If the thrust clearance is greater than maximum, re±
place the thrust washers as a set.
Thrust washer thickness:
2.440 ± 2.490 mm 10.0961 ± 0.0980 in.)
(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 wash±
ers (No.3 main bearing cap only).
HINT:
wKeep the lower bearing and main bearing cap
together.
wArrange the main bearing caps and lower thrust
washers in correct order. HINT:
wKeep the bearings, connecting rod and cap to±
gether.
wArrange the piston and connecting rod assembl±
ies in correct order.
9. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the main bearing cap
bolts in several passes, in the sequence shown.
± 5S±FE ENGINEENGINE MECHANICALEG1±101

(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 bear±
ings. If necessary, grind or replace the crankshaft. (c) Lift out the crankshaft.
HINT: Keep the upper bearing and upper thrust wash±
ers together with the cylinder block.
(h) Install the main bearing caps.
(See step 4 on page EG1±121)
Torque: 59 N±m (600 kgf±cm, 43 ft±lbf)
NOTICE: Do not turn the crankshaft.
(i) Remove the main bearing caps.
(See procedure (a) and (b) on the previous page) (f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
± 5S±FE ENGINEENGINE MECHANICALEG1±102

HINT: If replacing the cylinder block subassembly, the
bearing standard clearance will be:
No.3:
0.027 ± 0.054 mm (0.0011 ± 0.0021 in.)
Others
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 crank±
shaft.
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 cylin±
der block and crankshaft, then selecting the bearing
with the same number as the total. There are 5 sizes
of standard bearings, marked ª1º, ª2º, ª3º, ª4º and ª5º
accordingly.Measure the Plastigage at its widest point.
Standard clearance:
No.3
STD
0.025 ± 0.044 mm (0.0010 ± 0.0017 in.)
U/S 0.25
0.027 ± 0.067 mm (0.0011 ± 0.0026 in.)
Others
STD
0.015 ± 0.034 mm (0.00015 ± 0.0013 in.)
U/S 0.25
0.019 ± 0.059 mm (0.0007 ± 0.0023 in.)
Maximum clearance:
0.08 mm (0.0031 In.)
EXAMPLE: Cylinder block ª2º + Crankshaft ª11º
= Total number 3 (Use bearing ª3º)Cylinder block
Number marked
Use bearing
Crankshaft
± 5S±FE ENGINEENGINE MECHANICALEG1±103

Reference:
Cylinder block main journal bore diameter:
Mark ª1º
59.020 ± 59.026 mm (2.32318 ± 2.3239 in.)
Mark ª2º
59.026 ± 59.032 mm (2.3239 ± 2.3241 in.)
Mark ª3º
59.032 ± 59.038 mm (2.3241 ± 2.3243 in.)
Crankshaft journal diameter:
Mark ª0º
54.998 ± 55.003 mm (2.1653 ± 2.1655 in.)
Mark ª11º
54.993±54.998 mm (2.1651 ± 2.1653 in.)
Mark ª2º
54.988 ± 54.993 mm (2.1649 ± 2.1651 in.)
Standard sized bearing center wall thickness:
No±3
Mark ªIº
1.992 ± 1.995 mm (0.0784 ± 0.0785 in.)
Mark '2º
1.995 ± 1.998 mm (0.0785 ± 0.0787 in.)
Mark ª3º
1.998 ± 2.001 mm (0.0787 ± 0.0788 in.)
Mark '4º
2.001 ± 2.004 mm (0.0788 ± 0.0789 in.)
Mark '5'
2.004 ± 2.007 mm (0.0789 ± 0.0790 in.)
Others
Mark ªIº
1.997 ± 2.000 mm (0.0786 ± 0.0787 in.)
Mark '2'
2.000 ± 2.003 mm (0.0787 ± 0.0789 in.)
Mark ª3º
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.
10. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the upper bearings and upper thrust washers
from the cylinder block.
± 5S±FE ENGINEENGINE MECHANICALEG1±104

CYLINDER BLOCK INSPECTION
1. CLEAN CYLINDER BLOCK
A. Remove gasket material
Using a gasket scraper, remove all the gasket material
from the top surface of the cylinder block.
B. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the
cylinder block.
2. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR
FLATNESS
Using a precision straight edge and thickness gauge,
measure the surfaces contacting the cylinder head
gasket for warpage.
Maximum warpage:
0.05 mm (0.0020 In.)
If warpage is greater than maximum, replace the cylin±
der block.
3. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 4 cylin±
ders. If necessary, replace the cylinder block.HINT: Arrange the main bearing caps, bearings and
thrust washers in correct order.
± 5S±FE ENGINEENGINE MECHANICALEG1±105

Using a cylinder gauge, measure the cylinder bore
diameter at positions A, B and C in the thrust and axial
directions.
Standard diameter:
STD
Mark ª1º
87.000 ± 87.010 mm (3.4252 ± 3.4256 in.)
Mark ª2º
87.010 ± 87.020 mm (3.4256 ± 3.4260 in.)
Mark ª3º
87.020 ± 87.030 mm (3.4260 ± 3.4264 In.)
Maximum diameter:
STD
87.23 mm (3.4342 in.)
O/S 0.50
87.73 mm (3.4350 In.)
If the diameter is greater than maximum, rebore all the 4
cylinders. If necessary, replace the cylinder block. 4. INSPECT CYLINDER BORE DIAMETER
HINT: There are 3 sizes of the standard cylinder bore
diameter, marked ª1º, ª2º and ª3º accordingly. The
mark is stamped on the top of the cylinder block.
5. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 in.), using a
ridge reamer, grind the top of the cylinder.
± 5S±FE ENGINEENGINE MECHANICALEG1±106

PISTON AND CONNECTING ROD ASSY
DISASSEMBLY
1. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston
pin.
If any movement is felt, replace the piston and pin as
a set.
2. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compres±
sion rings.
3. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.(b) Remove the 2 side rails and oil ring by hand.
HINT: Arrange the rings in correct order only.
(b) Gradually heat the piston to 80±90
C (176±194
F).
± 5S±FE ENGINEENGINE MECHANICALEG1±107

PISTON AND CONNECTING ROD
INSPECTION
1. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the
piston top. HINT:
The piston and pin are a matched set.
Arrange 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.
(c) Using plastic±faced hammer and brass bar, lightly
tap out the piston pin and remove the connecting rod.
(b) Using a groove cleaning tool or broken ring, clean the
piston ring grooves.
± 5S±FE ENGINEENGINE MECHANICALEG1±108

(a) Using a micrometer, measure the piston diameter at
ring angles to the piston pin center line, 23.5 mm
(0.925 in.) from the piston head.
Piston diameter:
STD
Mark ªIº
86.85±86.86 mm (3.4193 ± 3.4197 in.)
Mark ª2º
86.86±86.87 mm (3.4197 ± 3.4201 In.)
Mark ª3º
86.87 ± 86.88 mm (3.4201 ± 3.4205 in.)
O/S 0.50
87.35 ± 87.38 mm (3.4390 ± 3.4402 in.)
(b) Measure the cylinder bore diameter in the thrust di±
rections.
(See step 4 on page EG1±106)
(c) Subtract the piston diameter measurement from the
cylinder bore diameter measurement.
Standard oil clearance:
0.14 ± 0.16 mm (0.0055 ± 0.0063 in.)
Maximum oil clearance:
0.18 mm (0.0071 in.)
If the oil clearance is greater than maximum, replace
all the 4 pistons and rebore all the 4 cylinders. If
necessary, replace the cylinder block.
HINT (Use new cylinder block): Use a piston with the
same number mark as the cylinder bore diameter
marked on the cylinder block.2. INSPECT PISTON
A. Inspect piston oil clearance
HINT: There are 3 sizes of the standard piston diame±
ter, marked ª1º, ª2º and ª3º accordingly. The mark is
stamped on the piston top.
± 5S±FE ENGINEENGINE MECHANICALEG1±109

(c) Using a thickness gauge, measure the end gap.
Standard and gap:
No.1
0.270 ± 0.500 mm (0.0106 ± 0.0197 in.)
No.2
0.350 ± 0.600 mm (0.0138 ± 0.0234 in.)
Oil (Side rail)
0.200 ± 0.550 mm (0.0079 ± 0.0217 in.)
Maximum end gap:
No.1
1.10 mm (0.0433 in.)
No.2
1.20 mm (0.0472 In.)
Oil (Side rail)
1.15 mm (0.0453 In.)
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
or replace the cylinder block. B. Inspect piston ring groove clearance
Using a thickness gauge, measure the clearance be±
tween new piston ring and the wall of the piston ring
groove.
Ring groove clearance:
No.1
0.040 ± 0.080 mm (0.0016 ± 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.
C. 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
bottom of the ring travel, 115 mm (4.53 in.) from the
top of the cylinder block.
± 5S±FE ENGINEENGINE MECHANICALEG1±110