Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Description

Cylinder block

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Description

Crankshaft

Bearing cap

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Description

Connecting rod

Bearing cap

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Description

Crankshaft
bearing
Thrust
washer
Connecting
rod bearing

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Description

Piston pin Piston

Piston
rings

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Cylinder block
Water jacket

Half skirt Deep skirt

G 4 G C 3 000000
Serial number
Production year
Engine capacity
Engine development order
Cylinder
Fuel

Made of cast iron (Diesel engine)

Linerless type Wet type liner Dry type liner
or aluminum
Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Gaskets and oil seals

Cylinder Head

Cylinder head gasket

Engine seal kit

Fire rings

Engine block

Liquid sealant

Oil pan

Oil seal
Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Cylinder Block

Cylinder block

Cylinder liner

Combustion stroke Compression stroke

Ridge

Cylinder wear

Thrust force

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Cylinder Block

1.Cylinder bore size

Location of cylinder bore STD size codes
(5VZ-FE engine)

Front

Bore size code Cylinder bore size

1 Small

3 Large

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Cylinder Block

2.Crankshaft main journal

bore size Location of main journal bore STD size codes
(1NZ-FE engine)

Bore size code Crankshaft main

journal bore size

0 Small

6 Large

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Crankshaft Upper bearing

Thrust bearing
Piston rings
Piston

Piston pin

Connecting
rod

Thrust bearing

Connecting Crankshaft Crankshaft Flywheel Lower bearing

rod bearing bearing journal
Crank pin Shaft pivot
1
2 3 4 5 6

5 and 2

6 and 1 3 and 4

Offset 6-cylinder crankshaft Oil bore Counter weight

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Crankshaft

Crank pin

Crank journal Balance weight

Crankshaft

Oil hole

REFERENCE:
Crankshaft Offset (1/3)
Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Piston and connecting rod

Valve recess
Piston top land Piston head
Ringzone

Piston boss

Steel ring inlay Cast inlay Compression ring

Oil ring
Piston skirt
Combustion pressure Piston pin
Piston boss Connecting rod
Piston

Connecting Front Large Bearing

rod

Small Bearing cap

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Crankshaft Offset

Combustion pressure Combustion pressure

Piston

Connecting rod

Crankshaft center

Offset

Offset crankshaft Center crankshaft

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Crankshaft

Example

Bearing cap

Bearing cap unit with ladder-frame construction

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Crankshaft

1.Main journal and crank

Location of main journal and crank pin STD size codes
pin size

Main journal STD

size codes Main journal STD
(1NZ-FE engine) size codes
(2JZ-GE engine)

Crank pin STD

size codes
(2JZ-GE engine)

Main journal or crank Main journal or

pin size codes crank pin size

1 Large
2

3
Small

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Crankshaft Bearing

1.Bearing size/
2.Undersize bearing
Upper halt-bearing
Oil groove Oil hole
Thrust washer

Bearing size code

Locking lip
Oil groove
Lower half-bearing

Bearing size code Bearing size

1
Thin

Thick

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Connecting Rod

1.Big end bore size

Connecting rod
Bearing cap

Oil jet

Big end bore

Front mark size code

Big end bore

Big bore size

Big end bore size
code

1 Large

3 Small

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Connecting Rod Bearing

1.Bearing Size/
2.Undersize Bearing

Oil hole

Bearing size code

Bearing size code Bearing size

1
Thin

Thick

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Bearing Selection

Oil clearance

Bearing Oil film

Oil clearance

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Bearing Selection

1.Bearing selection method

No.2

No.1 No.2 No.3 No.4

No.1
No.3 No.4
No.5 No.5

Bearing size cord

Cylinder block main journal

bore size code (A)
0-2 3-5 6 - 8 9 - 11
Crankshaft main journal
size code (B)

Example 7
A = 4, B = 3, A + B = 7

Use bearing size code 1 2 3 4

(2/2)
Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston

1.Description

Oval Circle
Small
Piston pin boss

Piston
skirt

Large
Truncated cone True cylinder

Cold Hot

(1/4)
Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston

2.Thrust force

Combustion pressure Compression pressure

Major thrust force Minor thrust force

(Combustion stroke) (Compression stroke)

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston

3.Piston slap (Side knocking)/

Piston slap
4.Operation of offset pistons

Offset piston

Center of piston pin Center of piston

Piston

Offset

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston

3.Piston slap (Side knocking)/

4.Operation of offset pistons

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston

5.Piston size
Piston size code and front mark
(5VZ-FE engine)

Piston size code

Front mark

REFERENCE:
Striations on the Piston Skirt (4/4)
Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston

Piston size code and front mark

(5VZ-FE engine)

Piston size code

Front mark

(4/4)
Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston

Piston size code and front mark

(5VZ-FE engine)

Piston size code

Front mark

(4/4)
Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Piston rings
Compression ring types

Ring diameter

Radial thickness
Ring side Diametral Tension
Tangential Tension
Ring face Width
Joint
Oil ring types

Oil vents

Channel
Contacting lands

Combustion
gas

Piston
Piston
Cylinder
Cylinder

Oil
Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston Ring

1.Description

Compression ring No.1

Compression ring No.2

Oil ring side rail (upper)

Oil rings Oil ring expander

Oil ring side rail (lower)

(1/4)
Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston Ring

2.Marks of ring
Size
Manufacturer

No.1 code mark

No.2 code mark

No.1 compression ring end gap

and oil ring expander end gap Oil ring side rail (lower) end gap

Oil ring side rail (upper) end gap No.2 compression ring end gap

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston Ring

3.Ring end gap

1NZ-FE engine:
110mm (4.33 in.)

Ring end gap

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Piston Ring

4.Ring pumping effect and

ring flutter

Cylinder

Engine oil

Piston

Piston ring

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Connecting rods dismantling, inspection and reassembling

Ridge Reamer Mark bearing caps

Checking Connecting
Identification mark Rod side play
1.8L : 18, 2.0 MPI : 20
2.0 TCI : TC, 2.4L : 24

Bearing

Identification
colour

Bearing cap
Front mark

Connecting Rod Size Mark

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Piston and piston pin dismantling, inspection and reassembling

Abnormal Removing piston

combustion rings

Overheated Cleaning piston

ring grooves

Fuel type mark

Piston grade mark

Checking piston ring
side clearance
Piston front mark
Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Crankshaft dismantling, inspection and reassembling

Screw driver

Dial gauge

Checking Crankshaft
end float

Journal
diameter grade
Pin diameter
grade
Front nose
Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Crankshaft main and connecting big end bearings

Scratched by dirt:
debris embedded into bearing
material

Lack of oil:
Overlay wiped out

Improper seating:
Bright (polished) sections

Tapered journal:
Overlay gone from entire surface

Radius ride

Fatigue failure:
Craters or pockets

Letters on cylinder block

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine block dismantling, inspection and reassembling

Clean bolt holes by Inserting new

using a tap core plugs

Crosshatch
pattern

LH-Bank
RH-Bank

Letters on cylinder block

Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Flywheel and balance shaft

Flywheel Purpose of the Flywheel

5.
1.
2. 2.
4.
3.

4.
1.
5.
3.

Balance shafts
Dual Mass Flywheel Purpose of the Balance shaft
Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Balance Shaft

va, vb: Crankshaft rotational speed

Va, Vb: Piston movable speed
La, Lb: Piston movable distance
va = vb
Va<Vb
La<Lb
Inertial forces

Lb Vb

La Va

vb
Balance shaft
va

Counterweight

A B

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Inspection Compression Pressure

1.Check compression pressure

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Diagnosis Technician >> Gasoline Engine >> Gasoline Engine

Engine Proper Striations on the Piston Skirt

Striation finish

Resin coating

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