Toyota Avalon Service & Repair Manual: Replacement

Toyota Avalon Service & Repair Manual / Engine / 2gr-fks Engine Mechanical / Cylinder Block / Replacement

REPLACEMENT

PROCEDURE

1. REPLACE STRAIGHT PIN

NOTICE:

If a straight pin is deformed, replace it.

(a) Using a plastic hammer, tap in new straight pins to the cylinder block sub-assembly.

*a

Front Side

*b

Rear Side

*c

Top Side

*d

Bottom Side

*e

RH Side

*f

23 mm (0.906 in.)

*g

6 mm (0.236 in.)

*h

11 mm (0.433 in.)

*i

9 mm (0.354 in.)

-

-

Standard Protrusion Height:

Item

Specified Condition

Pin (A)

23 mm (0.906 in.)

Pin (B)

6 mm (0.236 in.)

Pin (C)

11 mm (0.433 in.)

Pin (D)

9 mm (0.354 in.)

2. REPLACE STUD BOLT

NOTICE:

If a stud bolt is deformed or its threads are damaged, replace it.

(a) Using E8 and E10 "TORX" socket wrenches, install the stud bolts to the cylinder block sub-assembly.

*a

Front Side

*b

LH Side

*c

24 mm (0.9449 in.)

*d

12 mm (0.4724 in.)

*e

52 mm (2.05 in.)

*f

23 mm (0.906 in.)

*g

15 mm (0.591 in.)

*h

40 mm (1.57 in.)

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

3. REPLACE CONNECTING ROD SMALL END BUSH

(a) Using SST and a press, press out the connecting rod small end bush.

SST: 09222-30010

(b) Align the oil hole of a new connecting rod small end bush with the oil hole of the connecting rod.

*a

Oil Hole

(c) Using SST and a press, push in the connecting rod small end bush.

SST: 09222-30010

(d) Using a pin hole grinder, hone the connecting rod small end bush to obtain the standard oil clearance between the connecting rod small end bush and piston pin.

Standard Oil Clearance:

0.005 to 0.011 mm (0.000197 to 0.000433 in.)

(e) Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

HINT:

Check that the piston pin fits at a normal room temperature.

    Reassembly

    Cylinder Head Gasket

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