engine TOYOTA CAMRY V20 1986 Service Information

PREPARATION FOR DISASSEMBLY
1. (M/T)
REMOVE CLUTCH COVER AND DISC
2. (M/T)
REMOVE FLYWHEEL
3. (A/T)
REMOVE DRIVE PLATE
4 REMOVE REAR END PLATE
Remove the bolt and end plate.
5. INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY
6. REMOVE DISTRIBUTOR (See page IG±18)
7. REMOVE TIMING BELT AND PULLEYS
(See page EM±34)
8. REMOVE CYLINDER HEADS (See page EM±76)
9. REMOVE WATER PUMP (See page CO±9)
10. REMOVE OIL PAN AND OIL PUMP
(See page LU±17)
11. REMOVE OIL FILTER (See page LU±7)
12. REMOVE KNOCK SENSOR
Using SST, remove the knock sensor.
SST 09816±30010
13. REMOVE WATER BY±PASS PIPE
Remove the two bolts, two nuts and by±pass pipe.
14. REMOVE NO.2 IDLER PULLEY BRACKET
Remove the three bolts and mounting bracket.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±146

2. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
Standard thrust clearance: 0.150 ± 0.330 mm
(0.0059 ± 0.0130 in.)
Maximum thrust clearance: 0.38 mm (0.0150 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly. If necessary, replace the crank-
shaft.
3. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Using a punch or numbering stamp, place the rnatchmarks
on the connecting rod and cap to ensure correct reas-
sembly.
(c) Using a plastic±faced hammer, lightly tap the connect-
ing rod bolts and lift off the connecting rod cap.
HINT: Keep the lower bearing inserted with the connect-
ing cap.
DISASSEMBLY OF CYLINDER BLOCK
(See page EM±139)
1. REMOVE REAR OIL SEAL RETAINER
Remove the six bolts and retainer.
(b) Using SST, remove the connecting rod cap nuts.
SST 09011±38121
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±147

(i) Remove the connecting rod cap.
(j) Measure the Plastigage at widest point.
Standard oil clearance:
STD 0.028 ± 0.065 mm
(0.0011 ± 0.0026 in.)
U/S 0.25 0.027 ± 0.080 mm
(0.0011 ± 0.0031 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace
the bearings. If necessary, grind or replace the crank-
shaft. (e) Clean the 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 bearing.
If necessary, grind or replace the crankshaft.
(h) Install the connecting rod cap.
(See step 6 on page EM±165)
Torque: 1st 250 kg±cm (18 ft±ib, 25 N±m)
2nd turns 90°
NOTICE: Do not turn the crankshaft
(d) Cover the connecting rod bolts with a short piece of
hose to protect the crankshaft from damage.
(g) Lay a strip of Plastigage across the crank pin.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±148

HINT: If using a standard bearing, replace with one having
the same number marked on the connecting rod cap. There
are three sizes of standard bearings, marked
º1 º, º2º and º3º accordingly.
(Reference)
Standard sized bearing center wail thickness:
Mark º1º 1.484 ± 1.488 mm
(0.0584 ± 0.0586 in.)
Mark º2º 1.488 ± 1.492 mm
(0.0586 ± 0.0587 in.)
Mark º3º 1.492 ± 1.496 mm
(0.0587 ± 0.0589 in.)
(k) Completely remove the Plastigage.
4. REMOVE PISTON AND CONNECTING ROD
ASSEMBLIES
(a) Remove the all carbon from the piston ring ridge.
(b)Cover the connecting rod bolts.
(See page EM±145)
(c) Push the piston, connecting rod assembly and upper bear-
ing through the top of the cylinder block.
5. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while pry-
ing 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 (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness (STD size only):
2.440 ± 2.490 mm (0.0961 ± 0.0980 in.)
6. REMOVE MAIN BEARING CAP AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the main bearing cap
bolts in several passes in the sequence shown.HINT:
wKeep the bearing, connecting rod and cap together.
wArrange the piston and connecting rod assemblies in
correct order.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±149

(i) Remove the main bearing cap.
(j) Measure the Plastigage at its widest point.
Standard clearance:
STD 0.029 ± 0.056 mm
(0.0011 ± 0.0022 in.)
U/S 0.25 0.028 ± 0.080 mm
(0.0011 ± 0.0031 in.)
Maximum clearance: 0.08 mm (0.0031 in.)
HINT: If replacing the cylinder block sub±assembly, the
bearing standard clearance will be:
0.031 0.067 mm
(0.0012 ± 0.0026 in.)
If the oil clearance is greater than maximum, replace the
bearings. If necessary, grind or replace the crankshaft. (b) Using a screwdriver, pry up the main bearing cap, and
remove the main bearing cap, lower main bearings
and lower thrust washers (No. 2 journal position of
main bearing cap only).
HINT: Keep the lower main bearings and lower thrust
washers together with the main bearing cap.
(c) Lift out the crankshaft.
NOTE: Keep the upper main bearings and upper thrust
washers together with the cylinder block.
(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-
ing. If necessary, grind or replace the crankshaft.
(h) Install the main bearing cap.
(See step 4 on page EM±164)
Torque: 1 st 625 kg±cm (45 ft±Ib, 61 N±m)
2nd turns 90°
NOTICE: Do not turn the crankshaft
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±150

EXAMPLE: Cylinder block º2º + Crankshaft º1º
= Bearing ºT'
(Reference)
Cylinder block main journal bore diameter:
Mark º1 º 68.010 ± 68.0 16 mm
(2.6776 ± 2.6778'in.)
Mark º2º 68.016 ± 68.022 mm
(2.6778 ± 2.6780 in.)
Mark º3º 68.022 ± 68.028 mm
(2.6780 ± 2.6783 in.)
Crankshaft journal diameter:
Mark º0º 63.996 ± 64.000 mm
(2.5195 ± 2.5197 in.)
Mark º1º 63.990 ± 63.996 mm
(2.5193 ± 2.5195 in.)
Mark º2º 63.985 ± 63.990 mm
(2.5191 ± 2.5193 in.)
Standard sized bearing center wall thickness:
Mark º1 º 1.989 ± 1.992 mm
(0.0783 ± 0.0784 in.)
Mark º2º 1.992 ± 1.995 mm
(0.0784 ± 0.0785 in.)
Mark º3º 1.995 ± 1.998 mm
(0.0785 ± 0.0787 in.)
Mark º4º 1.998 ± 2.001 mm
(0.0787 ± 0.0788 in.)
Mark º5º 2.001 ± 2.004 mm
(0.0788 ± 0.0789 in.)
(k) Completely remove the Plastigage.
7. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the upper main bearings and upper thrust washers
from cylinder block.
HINT: Arrange the main bearings and thrust washers in cor-
rect order.HINT: If using a standard bearing, replace with one hav-
ing the same number. If the number of the bearing be
determined, select a bearing from the table below ac-
cording to the numbers imprinted on the cylinder block
and crankshaft. There are five sizes of standard bear-
ings, marked º1 º, º2º, º3º, ª4,ª and º5º accordingly.
Number marked
Cylinder block
Crankshaft
Bearing
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±151

5. INSPECT CYLINDER BORE DIAMETER
HINT: There are three sizes of the standard cylinder bore
diameter, marked º1 º, º2º and º3º accordingly. The mark is
stamped on the top of the cylinder block.
Using a cylinder gauge, measure the cylinder bore diameter
at positions A, B and C in the thrust axial directions.
Standard diameter:
STD mark º1 º 87.500 ± 87.510 mm
(3.4449 ± 3.4453 in.)
STD mark º2º 87.510 ± 87.520 mm
(3.4453 ± 3.4457 in.)
STD mark º3º 87.520 ± 87.530 mm
(3.4457 ± 3.4461 in.)
Maximum diameter:
STD 87.73 mm (3.4539 in.)
O/S 0.50 88.23 mm (3.4736 in.)
If the diameter is greater than maximum, rebore all the six
cylinders or replace the cylinder block.
INSPECTION OF CYLINDER BLOCK
1. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from
the cylinder block surface.
2. CLEAN CYLINDER BLOCK
Using a soft brush and solvent, clean the cylinder block.
3. INSPECT TOP OF CYLINDER BLOCK FOR FLATNESS
Using a ±precision straight edge and feeler gauge, measure
the surfaces contacting the cylinder head gasket for warp-
age.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder
block.
4. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the six cylinders or
replace the cylinder block.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±152

DISASSEMBLY OF PISTON AND
CONNECTING ROD ASSEMBLIES
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.6. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 in.), use a ridge ream-
er to machine the piston ring ridge at the top of the cylinder.
2. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the two compres-
sion rings.
(b) Remove the two side rails and oil ring expander by
hand.
HINT: Arrange the rings in correct order only.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±153

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