4A–FE engine is an in–line, 4–cylinder, 1.6 liter DOHC 16–valve engine. Manual - part 30

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: 0.160 – 0.312 mm

(0.0063 – 0.0123 in.)

Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, re-
place the connecting rod assembly. If necessary, re-
place the crankshaft.

3. REMOVE CONNECTING ROD CAPS AND CHECK OIL

CLEARANCE
(a) Check the matchmarks on the connecting rod and

cap to ensure correct reassembly.

DISASSEMBLY OF CYLINDER BLOCK

(See page

EM–223

)

1. REMOVE REAR OIL SEAL RETAINER

Remove the six bolts, retainer and gasket.

connecting rod bolts and lift off the connecting
rod cap.

HINT: Keep the lower bearing inserted with the
connecting cap.

(b) Remove the connecting rod cap nuts.

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ENGINE MECHANICAL

Cylinder Block (3S–GTE)

EM–234

(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
bearings. If necessary, grind or replace the crank–
shaft.

(h) Install the connecting rod cap.

(See step 7 on page

EM–255

)

Torque: 67 N–m (680 kgf–cm, 49 ft–lbf)

NOTICE: Do not turn the crankshaft.

(d) Cover the connecting rod bolts with a short piece

of hose to protect the crankshaft from damage.

(i) Remove the connecting rod cap.

(See procedures (b) and (c) above)

(g) Lay a strip of Plastigage across the crank pin.

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ENGINE MECHANICAL

Cylinder Block (3S–GTE)

EM–235

HINT: If using a standard bearing, replace it with one
having the same number marked on the connecting rod
cap. There are three sizes of standard bearings,
marked
“1” ”2” and ”3” accordingly.
Standard sized bearing center wall thickness:

Mark ”1 ” 1.484 –1.488 mm

(0.0584 – 0.0586 in.)

Mark ”2” 1.488 – 1.492 mm

(0.0586 – 0.0587 in.)

Mark ”3” 1. 492 – 1.496 mm

(0.0587 – 0.0589 in.)

(k) Completely remove the Plastigage.

4. REMOVE PISTON AND CONNECTING ROD

ASSEMBLIES
(a) Using a ridge reamer, remove all the carbon from the

top of the cylinder.

(b) Cover the connecting rod bolts.

(See page

EM–235

)

bearing through the top of the cylinder block.

5. CHECK CRANKSHAFT THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance
while prying the crankshaft back and forth with a screw-
driver.
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, re-
place the thrust washers as a set.
Thrust washer thickness: 2.440 – 2.490 mm

(0.0961 – 0.0980 in.)

(j) Measure the Plastigage at its widest point.
Standard oil clearance:

STD

0.024 – 0.055 mm
(0.0009 – 0.0022 in.)

U /S

0.25 0.023 – 0.069 mm
(0.0009 – 0.0027 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 crankshaft.

HINT:

•

Keep the bearings, connecting rod and cap to-
gether.

•

Arrange the piston and connecting rod assem-
blies in correct order.

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ENGINE MECHANICAL

Cylinder Block (3S–GTE)

EM–236

(b) Using the removed main bearing cap bolts, pry

the main bearing cap back and forth, and re-
move the main bearing caps, lower bearings
and lower thrust washers (No.3 main bearing
cap only).

HINT:

•

Keep the lower bearing and main bearing cap
together.

•

Arrange the main bearing caps and lower thrust
washers in correct order.

(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
bearings.
If necessary, grind or replace the crankshaft.

6. REMOVE MAIN BEARING CAPS AND CHECK OIL

CLEARANCE
(a) Remove the main bearing cap bolts.

(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.

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ENGINE MECHANICAL

Cylinder Block (3S–GTE)

EM–237

(j) 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 0.021 – 0.061 mm

(0.0008 – 0.0024 in.)

Others STD

0.015 – 0.034 mm
(0.0006 – 0.0013 in . )

U/S 0.25

0.029 – 0.069 mm
(0.0011 – 0.002 7 in . )

Maximum clearance: 0.08 mm (0.0031 in.)

HINT: If replacing the cylinder block subassembly, the bear-

ing 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 crankshaft.
HINT: If using a standard bearing, replace it with one hav-
ing the same number. If the number of the bearing cannot
be determined, select the correct bearing by adding to-
gether the numbers imprinted on the cylinder block and
crankshaft, then select the bearing with the same number
as the total. There are five sizes of standard bearings,
marked ”1,” ”2,” ”3,” ”4” and ”5” accordingly.

(h) Install the main bearing caps.

(See step 5 on page

EM–254

)

Torque: 59 N–m (600 kgf–cm, 43 ft–lbf)

NOTICE: Do not turn the crankshaft.

EXAMPLE: Cylinder block ”2” + Crankshaft ”1 ”

= Bearing ”3”

(i) Remove the main bearing caps.

(See procedures (a) and (b) above)

Number marked

Cylinder block

Crankshaft

Bearing

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ENGINE MECHANICAL

Cylinder Block (3S–GTE)

EM–238

(Reference)
Cylinder block main journal bore diameter:

Mark ”1 ” 59.020 – 59.026 mm

(2.3236 – 2.3239 in.)

Mark ”2” 59.026 – 59.032 mm

(2.3239 – 2.3241 in.)

Mark ”3” 59–032 – 59.038 mm

(2.3241 – 2.3243 in.)

Crankshaft journal diameter:

Mark ”0” 54.998 – 55.003 mm

(2.1653 – 2.1655 in.)

Mark ”1 ” 54–993 – 54. 998 mm

(2.1651 – 2.1653 in.)

Mark ”2” 54. 988 – 54. 993 mm

(2.1649 – 2.1651 in.)

Standard sized bearing center wall thickness:

No.3

Mark ”’1” 1.992 –1.995 mm

(0.0784 – 0.0785 in.)

Mark ”2” 1. 995 –1.998 mm

(0.0785 – 0.0787 in.)

Mark ”3” 1. 998 – 2.001 mm

(0.0787 – 0.0788 in.)

Mark ”4” 2.001 – 2.004 mm

(0.0788 – 0.0789 in.)

Mark ”5” 2.004 – 2.007 mm

(0.0789 – 0.0790 in.)

Others Mark ”’1” 1.997 – 2.000 mm

(0.0786 – 0.0787 in.)

Mark ”2” 2.000 – 2.003 mm

(0.0787 – 0.0789 in.)

Mark ”3” 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.

7. REMOVE CRANKSHAFT

(a) Lift out the crankshaft.
(b) Remove the upper bearings and upper thrust washers

from the cylinder block.

HINT: Arrange the main bearing caps, bearings and
thrust washers in correct order.

8. REMOVE OIL NOZZLES (See page

LU–31

)

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ENGINE MECHANICAL

Cylinder Block (3S–GTE)

EM–239

INSPECTION OF CYLINDER BLOCK

1. CLEAN CYLINDER BLOCK
A. Remove gasket material

Using a gasket scraper, remove all the gasket material
from the surface contacting the cylinder head.

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 feeler gauge, mea-
sure the surface contacting the cylinder head for
warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylin-
der block.

4. INSPECT CYLINDER BORE DIAMETER

HINT: There are three sizes of the standard cylinder
bore diameter, marked ”1 ”, ”2” and ”3” accordingly. The
mark is stamped on the top of the cylinder block.

3. INSPECT CYLINDER FOR VERTICAL SCRATCHES

Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder
block.

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ENGINE MECHANICAL

Cylinder Block (3S–GTE)

EM–240

Using a cylinder gauge, measure the cylinder bore
diameter at positions A, B and C in the thrust and
axial directions.
Standard diameter:

Mark 1” 86 . 000 – 86–010 mm

(3.3858 – 3.3862 in.)

Mark ”2” 86.010 – 86.020 mm

(3.3862 – 3.3866 in.)

Mark ”3” 86.020 – 86.030 mm

Maximum diameter: 86.23 mm (3.3949 in.)

If the diameter is greater than maximum, replace the
cylinder block

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.

2. REMOVE PISTON RINGS

(a) Using a piston ring expander, remove the two com-

pression rings.

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.

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Cylinder Block (3S–GTE)

EM–241

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