A) Use a scraper to remove carbon deposits and other carbon deposits from the piston crown.
b) Clean the piston grooves from deposits with a piece of a broken ring.
V) Clean the plunger with solvent and a soft hair brush.
Note: Do not use a metal brush.
2. Check the piston and piston rings.
A. Check clearance between piston and cylinder.
Note: there are three size groups of nominal piston diameter, indicated by marks (figures) "7", "2" And "3" respectively. The mark is applied on the piston crown with an edge in the direction perpendicular to the axis of the piston pin or on the piston crown in the center. Pay attention to the label (excavation) "before", along which the piston should be installed in the cylinder.
3S-FE, 4S-FE
3C-T
A) Using a micrometer, measure the diameter of the piston skirt at a distance of 25 mm from the surface of the piston crown (below the level of the piston ring grooves) and in a direction perpendicular to the axis of the piston pin, as shown in the figure.
Nominal piston diameter:
3S-FE:
- label "1" - 85.865 - 85.875 mm
- label "2" - 85.875 - 85.885 mm
- label "3" - 85.885 - 85.895 mm
- repair (0,50) - 86.365 - 86.395 mm
4S-FE:
- label "1" - 82.437 - 82.447 mm
- label "2" - 82.447 - 82.457 mm
- label "3" - 82.457 - 82.467 mm
- repair (0,50) - 82 937 - 82.967mm
- repair (0,75) - 83.187- 83.217 mm
ZS-T:
Nominal diameter:
- label "1" - 86.00 - 86.01 mm
- label "2" - 86.01 - 86.02 mm
- label "3" - 86.02 - 86.03 mm
Max Diameter:
- nominal - 86.23 mm
- repair (0,50) - 86.73 mm
b) Measure the cylinder diameters in the direction of the engine axis.
V) Find the difference between the measurements of the piston diameter and the cylinder diameter.
Clearance between cylinder and piston:
3S-FE:
- nominal - 0.125 - 0.145 mm
- maximum - 0.165 mm
4S-FE:
- nominal - 0.053 - 0.073 mm
- maximum - 0.12 mm
ZS-T:
- nominal - 0.112 - 0.132 mm
- maximum - 0.182 mm
If clearance is greater than maximum, replace all four pistons and bore all four cylinders. Replace the cylinder block if necessary.
Note: When using a new cylinder block, use the piston with the same mark (number), which is the diameter of the cylinder. The cylinder diameter is marked on the cylinder block in the places shown in the figure.
B. Check end clearance "compression ring - piston groove'' by measuring it with a flat feeler gauge as shown in the figure.
Rated Clearance:
Compression ring #1:
- 3S-FE, 4S-FE - 0.040 - 0.080 mm
- ZS-T - 0.047 - 0.111 mm
Compression ring #2:
- 3S-FE, 4S-FE - 0.030 - 0.070 mm
- ZS-T - 0.050 - 0.090 mm
Oil ring:
- ZS-T - 0.030-0.070 mm
If the clearance is more than acceptable, replace the piston.
B. Check the clearance in the piston ring lock.
A) Insert the piston ring into the cylinder.
b) Use the piston to push the ring 110 mm from the surface of the cylinder block as shown in the figure.
V) Use a flat feeler gauge to measure the gap in the lock.
3S-FE, 4S-FE:
Rated Clearance:
- compression ring No. 1 - 0.27 - 0.50 mm
- compression ring No. 2 - 0.27 - 0.51 mm
- oil scraper ring (scrapers) — 0.20-0.550 mm
Max Clearance:
- compression ring No. 1 - 1.10 mm
- compression ring No. 2 - 1.2 mm
- oil scraper ring (scrapers) - 1.15 mm
ZS-T:
Rated Clearance:
- compression ring No. 1 - 0.27 - 0.49 mm
- compression ring No. 2 - 0.35 - 0.62 mm
- oil scraper ring (scrapers) — 0.20 - 0.52 mm
Max Clearance:
- compression ring No. 1 - 1.29 mm
- compression ring No. 2 - 1.42 mm
- oil scraper ring (scrapers) - 1.32 mm
If the clearance in the lock is greater than the maximum, replace the piston ring. If the gap in the lock is greater than the maximum even with a new piston ring, bore all cylinders or replace the cylinder block.
D. Check piston pin.
When the piston is heated to 60°C, the piston pin should move in the piston without significant effort.
After checking, remove the piston pin.
3. Check the concentricity of the connecting rod.
A. Using the special tool and a feeler gauge, check the bending of the connecting rod as shown in the illustration. Maximum allowable bend per 100 mm length 0.05 mm
If twisting is more than acceptable, replace the connecting rod along with the connecting rod cap.
In the same way, check the twisting of the connecting rod, as shown in the figure.
Maximum twist per 100 mm length - 0.15 mm
B. Check up a backlash between a piston pin and a hole of the top head of a brown hair.
A) Using a inside gauge, measure the inside diameter of the connecting rod bushing.
Sleeve inner diameter:
- 3S-FE - 22.005 -22.017 mm
- 4S-FE - 20.013 - 20.025 mm
- ZS-T - 27.011-27.023 mm
b) Using a micrometer, measure the diameter of the piston pin.
Piston pin diameter:
- 3S-FE - 21.997 - 22.009 mm
- 4S-FE - 20.004 - 20.016 mm
- ZS-T - 27.000 -27.012 mm
V) Subtract the measured piston pin diameter from the measured bushing inside diameter.
Rated oil clearance:
- 3S-FE, 4S-FE - 0.005 -0.011 mm
- ZS-T - 0.007 - 0.015 mm
Max oil clearance: 0.05mm
If the clearance is greater than the maximum allowable, then replace the bushing. If necessary, replace the piston and piston pin assembly.
B. If necessary, replace the connecting rod bushing.
A) Using a drift and a press, press the bushing out of the connecting rod head.
b) (3S-FE, 4S-FE) Align the lubrication holes of the new bushing and connecting rod, and press the bushing.
(3C-T)
Install the bushing on the special tool, fixing it with a ball in the oil (lubricant) bushing holes.
Align the lubrication holes of the bushing and connecting rod.
Using a special tool and a press, press in the bushing.
V) Measure the piston pin clearance and, if necessary, grind or re-grind a new bushing to obtain the nominal clearance.
G) Check piston pin operation at normal room temperature. Coat the piston pin with engine oil and push it in as shown. The pin should pass freely into the hole in the connecting rod.
G. (3S-FE 4S-FE) Check connecting rod bolts.
A) Thread a nut onto each bolt and make sure the nut can be easily turned by hand over the full thread length of the bolt.
b) If the nut cannot be screwed on by hand, measure the outside diameter of the bolt thread with a caliper in the area where the threads are most worn.
Standard diameter:
- 3S-FE, 4S-FE - 7.860 - 8.000 mm
Minimum Diameter:
- 3S-FE, 4S-FE - 7.60mm
Note: If this area is difficult to detect visually, then measure at a distance of 15 mm from the end of the bolt, as shown in the figure.
If the outer diameter of the thread is less than the minimum, replace the connecting rod bolt and nut as a single assembly.