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EM-88
ENGINE MECHANICAL (5VZ-FE) - CYLINDER BLOCK
EM0Z8-02
INSPECTION
1. CLEAN CYLINDER BLOCK
(a) Remove the gasket material.
Using a gasket scraper, remove all the gasket material
from the top surface of the cylinder block.
(b) Clean the cylinder block.
Using a soft brush and solvent, thoroughly clean the cylin-
der block.
P21512
2. INSPECT CYLINDER BLOCK
(a) Inspect for flatness.
Using a precision straight edge and feeler gauge, mea-
sure 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 cylinder block.
Z14704
(b) Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 6 cylinders. If nec-
essary, replace the cylinder block.
P21514
Front : Mark 1, 2 or 3 (c) Inspect the cylinder bore diameter.
HINT:
There are 3 sizes of the standard cylinder bore diameter,
marked "1", "2" and "3" accordingly. The mark is stamped on the
No.1 No.3 No.5
top of the cylinder block.
No.2 No.4 No.6 EM6290
2002 4RUNNER (RM887U)
Author : Date : 900
EM-89
ENGINE MECHANICAL (5VZ-FE) - CYLINDER BLOCK
(d) Using a cylinder gauge, measure the cylinder bore diame-
ter at positions A, B and C in the thrust and axial direc-
tions.
Standard diameter:
Mark "1" 93.500 - 93.510 mm (3.6811 - 3.6815 in.)
Mark "2" 93.510 - 93.520 mm (3.6815 - 3.6819 in.)
Mark "3" 93.520 - 93.530 mm (3.6819 - 3.6823 in.)
Maximum diameter:
STD 93.730 mm (3.6902 in.)
O/S 0.50 94.230 mm (3.7098 in.)
(1) (1) Thrust
Front (2) Direction If the diameter is greater than maximum, rebore all the 6 cylin-
(2) Axial ders, If necessary, replace the cylinder block.
Direction (e) Remove the cylinder ridge.
10 mm
(0.39 in.) If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.
Middle
10 mm
(0.39 in.)
Z00145
3. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
P21450
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.
P21455
(c) Using solvent and a brush, thoroughly clean the piston.
NOTICE:
Do not use a wire brush.
P21448
2002 4RUNNER (RM887U)
Author : Date : 901
EM-90
ENGINE MECHANICAL (5VZ-FE) - CYLINDER BLOCK
Mark 4. INSPECT PISTON AND CONNECTING ROD
1, 2 or 3 Front (a) Inspect the piston oil clearance.
Mark
(Cavity) HINT:
There are 3 sizes of the standard piston diameter, marked "1",
26 mm "2" and "3" accordingly. The mark is stamped on the piston top.
(1) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, 26 mm
(1.02 in.) from the piston head.
Z14705 Piston diameter:
STD Mark "1" 93.356 - 93.666 mm (3.6754 - 3.6758 in.)
Mark "2" 93.367 - 93.376 mm (3.6759 - 3.6762 in.)
Mark "3" 93.377 - 93.386 mm (3.6763 - 3.6766 in.)
O/S 0.50 93.856 - 93.886 mm (3.6951 - 3.6963 in.)
(2) Measure the cylinder bore diameter in the thrust
directions (See step 5).
(3) Subtract the piston diameter measurement from the
cylinder bore diameter measurement.
Standard oil clearance:
0.134 - 0.154 mm (0.0053 - 0.0060 in.)
Maximum oil clearance: 0.174 mm (0.0069 in.)
If the oil clearance is greater than maximum, replace all the 6
pistons. If necessary, rebore all the 6 cylinders or replace the
cylinder block.
HINT:
: Mark 1, 2 or 3
Use a new cylinder block: Use a piston with the same number
mark as the standard bore diameter marked on the cylinder
block.
No.1 No.3 No.5
No.2 No.4 No.6
Mark 1, 2 or 3
A06832
EM6290 A07646
2002 4RUNNER (RM887U)
Author : Date : 902
EM-91
ENGINE MECHANICAL (5VZ-FE) - 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 piston ring groove.
Standard 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 not as specified, replace the piston.
P21456
(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, 115 mm (4.53 in.) from
the top of the cylinder block.
115 mm
Z14733
(3) Using a feeler gauge, measure the ring end gap.
Ring end gap:
Piston ring STD mm (in.) Maximum mm (in.)
0.300 - 0.500
No.1 1.100 (0.0433)
(0.0118 - 0.0197)
0.400 - 0.600
No.2 1.200 (0.0472)
(0.0157 - 0.0236)
0.150 - 0.550
Oil (Side rail) 1.150 (0.0453)
EM7639 (0.0059 - 0.0217)
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 6 cylinders or replace the cylinder block.
(d) Inspect the piston pin fit.
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