a) Using a scraper, remove carbon deposits from the piston bottom.
b) Using the broken ring, clean the piston ring grooves.
c) Using solvent and a soft brush, thoroughly clean the piston.
Caution: Do not use wire (metal) brush.
2. Check the piston diameter and the clearance between the piston and the cylinder.
Note: There are three nominal piston sizes by diameter, marked "1", "2" and "3" respectively. The marking is applied by stamping on the piston bottom.
a) Using a micrometer, measure the piston diameter at a right angle to the pin axis at a distance of 58 mm for 2L, 2L-T, 1KZ-T engines and 56 mm for 3L engines from the piston bottom.
Nominal piston diameter:
Engines 2L, 2L-T
- Marking "1" - 91.94 - 91.95 mm
- Marking "2" - 91.95 - 91.96 mm
- Marking "3" - 91.96 - 91.97 mm
Engine 3L, 1KZ-T
- Marking "1" - 95.94 - 95.95 mm
- Marking "2" - 95.95 - 95.96 mm
- Marking "3" - 95.96 - 95.97 mm
Repair (+0.50 mm):
- 2L, 2L-T engines — 92.44 - 91.47 mm
- Engine 3L 96.44 - 96.47 mm
- Engine 1KZ-T — 96.44 - 96.47 mm
Repair (+0.75 mm):
- Engine 1KZ-T — 96.69 - 96.72 mm
3 repair (+1.00 mm):
- Engine 1KZ-T — 96.94 - 96.97 mm
b) Measure the diameter of the cylinder in the transverse direction (see above)
c) Subtract the piston diameter measurement from the cylinder diameter measurement.
Nominal clearance - 0.05 - 0.07 mm
Maximum gap - 0.14 mm
If the clearance value exceeds the maximum permissible value, replace four pistons and bore all four cylinders. If necessary, replace the cylinder block.
Note: When installing a nominal size piston, the markings on the old and new pistons must match the markings on the cylinder block.
L-series engines
KZ series engines
3. Check the gap between the ring and the piston groove using a feeler gauge.
Gaps:
Ring #1:
- series L - 0.028 - 0.077 mm
- kZ series - 0.060 - 0.110 mm
Ring #2:
- except 2L-T — 0.060 - 0.105 mm
- only 2L-T - 0.070 - 0.115 mm
Oil scraper:
- series L - 0.030 - 0.070 mm
- kZ series - 0.020 - 0.060 mm
Maximum gap - 0.20 mm
If the clearance is greater than the permissible limit, replace the piston.
4. Check the piston ring gap.
a) Install the ring into the cylinder.
b) Using a piston, push the piston ring to a depth of 140 mm (L series) or 120 mm (KZ series) from the parting plane of the cylinder block.
c) Using a feeler gauge, measure the gap in the ring lock.
Nominal clearance in the lock:
ring no. 1
- series L 0.35 - 0.65 mm
- kZ series 0.35 - 0.57 mm
ring no. 2
- series L 0.30 - 0.60 mm
- kZ series 0.40 - 0.60 mm
- oil scraper - 0.20 - 0.50 mm
Maximum clearance:
ring no. 1
- l series - 1.50 mm
- kZ series - 1.03 mm
ring no. 2
- l series - 1.40 mm
- kZ series - 1.10 mm
oil scraper
- l series - 1.40 mm
- kZ series - 0.87 mm
If the gap in the ring lock exceeds the maximum permissible value, replace the piston ring.
If this gap exceeds the maximum permissible value even after installing a new ring, then bore all four cylinders or replace the cylinder block.
5. Check the fit of the piston pin: at a piston temperature of 60°C (L series) or 80°C (KZ series), the pin should enter the piston by hand.
6. Check the condition of the connecting rod.
A. Using a connecting rod tester, check the connecting rods for bending and twisting.
Maximum bending 0.05 mm (L series) or 0.03 mm (KZ series) per 100 mm of length.
Maximum twist 0.15 mm per 100 mm length.
If the bend or twist exceeds the maximum allowable value, replace the connecting rod.
B. Measure the diameter of the connecting rod bolt.
Nominal diameter - 8.40 - 8.60 mm
Minimum diameter - 8.20 mm
If the diameter is less than the minimum allowable value, replace the connecting rod bolt.
B. Check the clearance between the piston pin and the connecting rod upper head.
a) Measure the inner diameter of the connecting rod bushing.
Inner diameter of the bushing:
- 2L(T) — 27.008 - 27.02 mm
- 3L — 29.008-29.02 mm
- 1KZ-T - 34.012 - 34.024 mm
b) measure the diameter of the piston pin.
Piston pin diameter:
- 2L(T) — 27,000-27,012 mm
- 3L — 29,000-29,012 mm
- 1KZ-T - 34,000 - 34,012 mm
c) Subtract the piston pin diameter measurement from the bushing inner diameter measurement.
Nominal clearance
- series L - 0.004 - 0.012 mm
- kZ series - 0.008 -0.016 mm
Maximum clearance
- l series - 0.05 mm
- kZ series - 0.03 mm
7. If necessary, replace the connecting rod bushings.
A. Remove the connecting rod bushings. Using a jig and a press, press out the bushing.
B. Install new connecting rod bushings.
a) Using a round file, lightly file away any rough spots on the upper connecting rod head.
b) Install the sleeve on the fixture so that the ball of the fixture enters the hole in the sleeve.
c) Align the lubrication holes of the bushing and connecting rod.
d) Using the fixture and press, press in the bushing.
The material was taken from a resource TOYOTAMAN
d) Using a piston pin hole grinder, hone the bushing until the nominal bushing-to-piston pin clearance is achieved (see above).
e) Check the piston pin fit at room temperature. Lubricate the piston pin with engine oil, then push it into the connecting rod upper head bushing with your thumb.
