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EM-108
ENGINE MECHANICAL (2UZ-FE) - CYLINDER BLOCK
EM0EB-20
INSPECTION
1. CLEAN CYLINDER BLOCK
(a) Using a gasket scraper, remove all the gasket material
from the top surface of the cylinder block.
(b) Using a soft brush and solvent, thoroughly clean the cylin-
der block.
A04849
2. INSPECT CYLINDER BLOCK
(a) Inspect for flatness.
Using a precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder head and main
bearing cap for warpage.
Maximum warpage: 0.07 mm (0.0028 in.)
If warpage is greater than maximum, replace the cylinder block.
Cylinder Block Side
Main Bearing Cap Side
A04850
A04210
A04212 A05178
(b) Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 8 cylinders and re-
place all the 8 pistons. (See page EM-115) If necessary, re-
place the cylinder block.
A04853
EM-109
ENGINE MECHANICAL (2UZ-FE) - CYLINDER BLOCK
(c) Inspect the cylinder bore diameter.
No.2 No.4 No.6 No.8 HINT:
There is 1 size of the standard cylinder bore diameter, marked
Front "2" accordingly. The mark is stamped on the top of the cylinder
block.
No.1 No.3 No.5 No.7
: Mark 2 A04211
Thrust Using a cylinder gauge, measure the cylinder bore diame-
1
11 Direction ter at positions A and B in the thrust and axial directions.
Front 2 Standard diameter:
2 Axial
Direction
94.010 to 94.023 mm (3.7012 to 3.7017 in.)
Maximum diameter:
STD 94.223 mm (3.7096 in.)
10 mm
A (0.39 in.) O/S 0.50 94.723 mm (3.7292 in.)
If the diameter is greater than maximum, rebore all the 8 cylin-
B
ders and replace all the 8 pistons. (See page EM-115) If neces-
10 mm sary, replace the cylinder block.
(0.39 in.)
A04262
A04851 cmc0382
(d) Remove the cylinder ridge.
If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.
Ridge
Reamer A04852
(e) Using vernier calipers, measure the thread outside diam-
eter of the main bearing cap bolt.
Standard diameter:
10.760 to 10.970 mm (0.4236 to 0.4319 in.)
Minimum diameter: 10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the cap bolt.
50 - 64 mm (1.97 - 2.52 in.) A05138
EM-110
ENGINE MECHANICAL (2UZ-FE) - CYLINDER BLOCK
3. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
A04877
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.
A04878
(c) Using solvent and a brush, thoroughly clean the piston.
NOTICE:
Do not use a wire brush.
A04879
4. INSPECT PISTON AND CONNECTING ROD
Mark 2
(a) Inspect the piston oil clearance.
HINT:
Front
Mark There is 1 size of the standard piston diameter, marked "2" ac-
cordingly. 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, 30.75 mm
30.75 mm (1.2106 in.) from the piston head.
A23611 Piston diameter:
STD Mark "2" 93.912 to 93.940 mm (3.6973 to 3.6984 in.)
O/S 0.50 94.392 to 94.440 mm (3.7162 to 3.7181 in.)
(2) Measure the cylinder bore diameter in the thrust
directions (see step 2 above).
EM-111
ENGINE MECHANICAL (2UZ-FE) - CYLINDER BLOCK
(3) Subtract the piston diameter measurement from the
cylinder bore diameter measurement.
Standard oil clearance:
0.030 to 0.071 mm (0.0012 to 0.0028 in.)
Maximum oil clearance: 0.13 mm (0.0051 in.)
If the oil clearance is greater than maximum, replace all the 8
pistons and rebore all the 8 cylinders. (See page EM-115) If
necessary, replace the cylinder block.
HINT
Cylinder Block Use a new cylinder block:
No.2 No.4 No.6
S Use a piston with the same number mark as the cylinder
No.8
diameter number marked on the cylinder block.
Front
No.1 No.3 No.5 No.7
: Mark 2
Mark 2
A23615
(b) Inspect the piston ring groove clearance.
Using a feeler gauge, measure the clearance between
the new piston ring and the wall of the ring groove.
Ring groove clearance:
No.1 0.030 to 0.080 mm (0.0012 to 0.0031 in.)
No.2 0.020 to 0.060 mm (0.0008 to 0.0024 in.)
If the clearance is not as specified, replace the piston.
A04880
(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 to the bot-
tom of the ring travel, 105 mm (4.13 in.) from the top
of the cylinder block.
105 mm
A04872
EM-112
ENGINE MECHANICAL (2UZ-FE) - CYLINDER BLOCK
(3) Using a feeler gauge, measure the end gap.
Standard end gap:
No.1 0.300 to 0.400 mm (0.0118 to 0.0157 in.)
No.2 0.450 to 0.600 mm (0.0177 to 0.0236 in.)
Oil (Side rail) 0.100 to 0.350 mm (0.0039 to 0.0138 in.)
Maximum end gap:
No.1 1.10 mm (0.0433 in.)
EM7639
No.2 1.30 mm (0.0512 in.)
Oil (Side rail) 0.75 mm (0.0295 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 8 cylinders (See page EM-115) or replace
the cylinder block.
(d) Inspect the piston pin fit.
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