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EM-115
ENGINE MECHANICAL (2UZ-FE) - CYLINDER BLOCK
EM123-05
REPLACEMENT
1. REPLACE OVERSIZED (O/S) PISTONS FOR CYL-
INDER BORING
HINT:
S Bore all the 8 cylinders to match the oversized piston out-
side diameter.
S Replace all the piston rings with ones to match the over-
30.75 mm
sized pistons.
A23612
(a) Keep 8 new oversized pistons.
O/S 0.50 piston diameter:
94.392 to 94.440 mm (3.7162 to 3.7181 in.)
(b) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 30.75 mm (1.2106 in.)
from the piston head.
(c) Calculate the size to be rebored for each cylinder as fol-
lows:
Size to be rebored = P + C - H
P = Piston diameter
C = Piston clearance:
0.030 to 0.071 mm (0.0012 to 0.0028 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.
2. REPLACE CONNECTING ROD BUSHINGS
(a) Using SST and a press, press out the bushing.
SST SST 09222-30010
P20665
(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
Oil
Hole
P20666
EM-116
ENGINE MECHANICAL (2UZ-FE) - CYLINDER BLOCK
(d) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance (See page EM-100) be-
tween the bushing and piston pin.
P20667
(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.
3. REPLACE CRANKSHAFT FRONT OIL SEAL (See
page LU-13)
P20668
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.
A04868
(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 09223-56010
(3) Apply MP grease to the oil seal lip.
SST
A04867
(b) If the rear oil seal retainer 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.
Cut Position A04858
EM-117
ENGINE MECHANICAL (2UZ-FE) - CYLINDER BLOCK
(3)Apply MP grease to a new oil seal lip.
SST (4)Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223-56010
A04859
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