Toyota Avalon (XX50): Cylinder Block

*1

CONNECTING ROD BEARING

*2

CRANKSHAFT

*3

CRANKSHAFT BEARING

*4

CRANKSHAFT THRUST WASHER SET

*5

CYLINDER BLOCK SUB-ASSEMBLY

*6

NO. 1 OIL NOZZLE SUB-ASSEMBLY

*7

PISTON

*8

PISTON RING SET

*9

STUD BOLT

*10

PISTON PIN

*11

PISTON PIN HOLE SNAP RING

*12

CONNECTING ROD SUB-ASSEMBLY

*13

CONNECTING ROD CAP

*14

CRANKSHAFT BEARING CAP

*15

SEAL WASHER

*16

NO. 1 COMPRESSION RING

*17

NO. 2 COMPRESSION RING

*18

OIL RING

*19

UPPER SIDE RAIL

*20

OIL RING EXPANDER

*21

LOWER SIDE RAIL

*22

CONNECTING ROD

*23

CONNECTING ROD SMALL END BUSH

*24

STRAIGHT PIN

*25

CONNECTING ROD BOLT

*26

CRANKSHAFT BEARING CAP SET BOLT

N*m (kgf*cm, ft.*lbf): Specified torque

●

Non-reusable part

*T1

1st: 24.5 (250, 18)

2nd: Turn 90°

*T2

1st: 61 (622, 45)

2nd: Turn 90°

Battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane departure alert system (w/ Steering Control)

Pre-collision system

Intelligent Clearance Sonar System*1

Lighting System (for Gasoline Model with Cornering Light)

Memorize steering angle neutral point

Parking Assist Monitor System

Panoramic View Monitor System

Replacement of ECM

Vehicle Identification Number (VIN) registration

MIL comes on

ECU communication ID registration (Immobiliser system)

Engine start function

• Replacement of throttle body with motor assembly
• Cleaning the deposits from the throttle body with motor assembly
• Replacement of cylinder head sub-assembly
• Replacement of camshaft (for intake or exhaust camshaft)
• Replacement of camshaft timing gear assembly
• Replacement of camshaft timing exhaust gear assembly
• Replacement of piston or piston ring
• Replacement of fuel injector assembly (for port injection)
• Replacement of fuel injector assembly (for direct injection)
• Replacement of fuel pump assembly (for high pressure side)
• Replacement of engine coolant temperature sensor
• Replacement of spark plug
• Replacement of ignition coil assembly
• Air leaks from intake system
• Gas leak from exhaust system is repaired
• Replacement of knock control sensor

Inspection after repair

• Poor idle, etc.
• Engine start function, etc.

Replacement of automatic transaxle assembly

• Perform reset memory
• Input transaxle compensation code into ECM
• Perform road test to allow ECM to learn

• Large shift shock
• Deterioration of fuel efficiency

for Initialization

for Registration

Replacement of ECM

(If transaxle compensation code read from ECM)

• Perform reset memory*2
• Transfer transaxle compensation code
• Perform road test to allow ECM to learn

Replacement of ECM

(If transaxle compensation code not read from ECM)

• Perform reset memory*2
• Reset transaxle compensation code
• Perform road test to allow ECM to learn

Replacement of automatic transaxle fluid

ATF thermal degradation estimate reset

The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly

Replacement of ECM

Code registration (Smart Key System (for Start Function))

• Wireless Door Lock Control System
• Smart Key System (for Entry Function)
• Smart Key System (for Start Function)
• Steering lock function

Suspension, tires, etc.

• Measure ultrasonic sensor detection angle
• Ultrasonic sensor detection angle registration

• Intelligent Clearance Sonar System
• Intuitive Parking Assist System

Rear television camera assembly optical axis adjustment (Back camera position setting)

Parking Assist Monitor System

for Initialization

for Calibration

• Parking assist ECU initialization
• Adjust steering angle
• Television camera assembly optical axis adjustment (Back camera position setting)

Panoramic View Monitor System

for Initialization

for Calibration

Perform headlight ECU sub-assembly LH initialization

Lighting system (for Gasoline Model with Cornering Light)

Front wheel alignment adjustment

Perform system variant learning and acceleration sensor zero point calibration.

• VSC is disabled or malfunctions
• DTCs are output
• Slip indicator light illuminates
• ABS warning light illuminates

Front of Engine

(c) Using the 2 removed connecting rod bolts, remove the connecting rod cap and lower connecting rod bearing by wiggling the connecting rod cap right and left.

HINT:

Keep the lower connecting rod bearing installed to the connecting rod cap.

(d) Using a ridge reamer, remove all of the carbon from the top of the cylinder.

(a) Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring.

(a) Check the fitting condition between the piston and piston pin.

(1) Try to move the piston back and forth on the piston pin.

HINT:

If abnormal movement is felt, replace the piston and piston pin as a set.

(2) Gradually heat the piston to approximately 80°C (176°F).

CAUTION:

Be sure to wear protective gloves.

(3) Using a brass bar and a hammer, lightly tap out the piston pin and remove the connecting rod sub-assembly.

HINT:

• The piston and piston pin are a matched set.
• Arrange the removed parts in such a way that they can be reinstalled to their original locations.

(c) Using a gasket scraper, remove any carbon from the piston top.

NOTICE:

Be careful not to scratch the piston.

(d) Using a groove cleaning tool or a broken ring, clean the piston ring grooves.

(e) Using solvent and a brush, thoroughly clean the piston.

NOTICE:

Do not use a wire brush.

(a) Uniformly loosen and remove the 8 crankshaft bearing cap set bolts and 8 seal washers in several steps in the order shown in the illustration.

(b) Uniformly loosen the 16 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

(c) Using a screwdriver with its tip wrapped with protective tape, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and 4 lower crankshaft bearings as a set.

NOTICE:

• Push up the crankshaft bearing cap slowly and evenly, alternating between the right and left side so that the crankshaft bearing cap can be removed.
• Be careful not to damage the contact surfaces of the cylinder block sub-assembly and the crankshaft bearing cap.

(a) Remove the crankshaft thrust washer set from the cylinder block sub-assembly.

(a) Using a 5 mm hexagon socket wrench, remove the 3 bolts and 3 No. 1 oil nozzle sub-assemblies.

(b) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

Standard Thrust Clearance:

0.15 to 0.40 mm (0.00591 to 0.0157 in.)

Maximum Thrust Clearance:

0.50 mm (0.0197 in.)

HINT:

If the thrust clearance is more than the maximum, replace the connecting rod sub-assembly. If necessary, replace the crankshaft.

(c) Lay a strip of Plastigage on the crank pin.

*a

Front Mark

Front of Engine

(g) Measure the Plastigage at its widest point.

Standard Oil Clearance:

0.045 to 0.067 mm (0.00177 to 0.00264 in.)

Maximum Oil Clearance:

0.070 mm (0.00276 in.)

HINT:

• If the oil clearance is more than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.
• If replacing a connecting rod bearing, select a new one with the same number as marked on the connecting rod cap. There are 4 sizes of standard connecting rod bearings, marked "1", "2", "3" or "4" accordingly.

Standard Connecting Rod Diameter:

Standard Connecting Rod Bearing Center Wall Thickness:

Standard Crankshaft Pin Diameter:

52.992 to 53.000 mm (2.08630 to 2.08661 in.)

NOTICE:

Completely remove the Plastigage after the measurement.

(a) Using a precision straightedge and feeler gauge, check the surfaces which contact the cylinder head gasket for warpage.

Maximum Warpage:

0.07 mm (0.00276 in.)

HINT:

If the warpage is more than the maximum, replace the cylinder block sub-assembly.

*a

Thrust Direction

*b

Axial Direction

*c

10 mm (0.394 in.)

*d

Center

Front of Engine

(a) Using a micrometer, measure the piston diameter at a right angle to the piston center line where the distance from the bottom of the piston is as specified.

Distance:

9.2 mm (0.362 in.)

Reference Diameter (New Parts):

93.962 to 93.992 mm (3.69928 to 3.70047 in.)

Minimum Diameter:

93.830 mm (3.69409 in.)

HINT:

If the piston diameter is less than the minimum, replace the piston and piston pin as a set.

(a) Using a feeler gauge, measure the clearance between a new piston ring set and the wall of the ring groove.

Standard Ring Groove Clearance:

HINT:

If the clearance is not as specified, replace the piston.

(a) Using a caliper gauge, measure the inside diameter of the piston pin hole.

Standard Piston Pin Hole Inside Diameter:

(b) Using a micrometer, measure the piston pin diameter.

Standard Piston Pin Diameter:

(d) Using a caliper gauge, measure the inside diameter of the connecting rod small end bush.

Standard Bushing Inside Diameter:

(e) Subtract the piston pin diameter measurement from the bushing inside diameter measurement.

Standard Oil Clearance:

0.005 to 0.011 mm (0.000197 to 0.000433 in.)

Maximum Oil Clearance:

0.030 mm (0.00118 in.)

HINT:

• If the oil clearance is more than the maximum, replace the connecting rod small end bush.
• If necessary, replace the connecting rod sub-assembly and piston sub-assembly with pin.

(b) Using a piston, push in the piston ring slightly beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block sub-assembly.

(c) Using a feeler gauge, measure the end gap.

Standard End Gap:

Maximum End Gap:

HINT:

If the end gap is more than the maximum, replace the piston ring. If the end gap is more than the maximum even with a new piston ring, replace the cylinder block sub-assembly.

(b) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

Standard Thrust Clearance:

0.04 to 0.24 mm (0.00157 to 0.00945 in.)

Maximum Thrust Clearance:

0.30 mm (0.0118 in.)

Standard Thrust Washer Thickness:

2.43 to 2.48 mm (0.0957 to 0.0976 in.)

HINT:

If the thrust clearance is more than the maximum, replace the crankshaft thrust washer set. If necessary, replace the crankshaft.

(a) Using a vernier caliper, measure the diameter of the connecting rod bolt at several points within the area shown in the illustration.

Standard Diameter:

7.2 to 7.3 mm (0.283 to 0.287 in.)

Minimum Diameter:

7.0 mm (0.276 in.)

HINT:

• If the diameter is less than the minimum, replace the connecting rod bolt.
• Diameter measurements should be done at several points.
• If the diameter is less than the minimum, replace the connecting rod bolt with a new one. Failure to do so may lead to engine damage.
• If there is any thread deformation, replace the connecting rod bolt with a new one.

(3) Using a dial indicator, measure the runout at the center of each journal.

Maximum Runout:

0.06 mm (0.00236 in.)

HINT:

If the runout is more than the maximum, replace the crankshaft.

(1) Using a micrometer, measure the diameter of each main journal.

Standard Journal Diameter:

60.988 to 61.000 mm (2.40110 to 2.40157 in.)

HINT:

If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.

(1) Using a micrometer, measure the diameter of each crank pin.

Standard Crank Pin Diameter:

52.992 to 53.000 mm (2.08630 to 2.08661 in.)

HINT:

If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.

(e) Lay a strip of Plastigage across each journal.

(i) Measure the Plastigage at its widest point.

Standard Oil Clearance:

Maximum Oil Clearance:

NOTICE:

Completely remove the Plastigage after the measurement.

HINT:

If the oil clearance is more than the maximum, replace the crankshaft bearings. If necessary, replace the crankshaft.

*a

Number Mark

*b

No. 2 and No. 3 Crankshaft Bearing

*c

No. 1 and No. 4 Crankshaft Bearing

*d

No. 1

*e

No. 2

*f

No. 3

*g

No. 4

*h

20.9 mm (0.823 in.)

*i

17.9 mm (0.705 in.)

-

-

0 to 3

"1"

"1"

4 to 6

"1"

"2"

7 to 9

"2"

"2"

10 to 12

"2"

"3"

13 to 15

"3"

"3"

16 to 18

"3"

"4"

19 to 21

"4"

"4"

22 to 24

"4"

"5"

25 to 28

"5"

"5"

"00"

60.999 to 61.000 mm (2.40153 to 2.40157 in.)

"01"

60.998 to 60.999 mm (2.40149 to 2.40153 in.)

"02"

60.997 to 60.998 mm (2.40145 to 2.40149 in.)

"03"

60.996 to 60.997 mm (2.40141 to 2.40145 in.)

"04"

60.995 to 60.996 mm (2.40137 to 2.40141 in.)

"05"

60.994 to 60.995 mm (2.40133 to 2.40137 in.)

"06"

60.993 to 60.994 mm (2.40129 to 2.40133 in.)

"07"

60.992 to 60.993 mm (2.40126 to 2.40129 in.)

"08"

60.991 to 60.992 mm (2.40122 to 2.40126 in.)

"09"

60.990 to 60.991 mm (2.40118 to 2.40122 in.)

"10"

60.989 to 60.990 mm (2.40114 to 2.40118 in.)

"11"

60.988 to 60.989 mm (2.40110 to 2.40114 in.)

"1"

2.497 to 2.500 mm (0.09831 to 0.09843 in.)

"2"

2.501 to 2.503 mm (0.09846 to 0.09854 in.)

"3"

2.504 to 2.506 mm (0.09858 to 0.09866 in.)

"4"

2.507 to 2.509 mm (0.09870 to 0.09878 in.)

"5"

2.510 to 2.512 mm (0.09882 to 0.09890 in.)

"1"

2.478 to 2.481 mm (0.09756 to 0.09768 in.)

"2"

2.482 to 2.484 mm (0.09772 to 0.09780 in.)

"3"

2.485 to 2.487 mm (0.09783 to 0.09791 in.)

"4"

2.488 to 2.490 mm (0.09795 to 0.09803 in.)

"5"

2.491 to 2.493 mm (0.09807 to 0.09815 in.)

"1"

2.476 to 2.479 mm (0.09748 to 0.09760 in.)

"2"

2.480 to 2.482 mm (0.09764 to 0.09772 in.)

"3"

2.483 to 2.485 mm (0.09776 to 0.09783 in.)

"4"

2.486 to 2.488 mm (0.09787 to 0.09795 in.)

"5"

2.489 to 2.491 mm (0.09799 to 0.09807 in.)

"1"

2.493 to 2.496 mm (0.09815 to 0.09827 in.)

"2"

2.497 to 2.499 mm (0.09831 to 0.09839 in.)

"3"

2.500 to 2.502 mm (0.09843 to 0.09850 in.)

"4"

2.503 to 2.505 mm (0.09854 to 0.09862 in.)

"5"

2.506 to 2.508 mm (0.09866 to 0.09874 in.)

(a) Using a vernier caliper, measure the diameter of the threads at the measurement point.

Standard Diameter:

10.8 to 11.0 mm (0.425 to 0.433 in.)

Minimum Diameter:

10.7 mm (0.421 in.)

Measurement Point (Distance from the Seat):

40 mm (1.57 in.)

HINT:

• If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt. Failure to do so may lead to engine damage.
• If there is any thread deformation, replace the crankshaft bearing cap set bolt with a new one.

(a) Push the check valve with a pin to check that it is not stuck.

HINT:

If the check valve is stuck, replace the No. 1 oil nozzle sub-assembly.

(c) While covering (A), blow air into (B). Check that air does not leak through (C). Perform the check again while covering (B) and blowing air into (A).

HINT:

If air leaks, clean or replace the No. 1 oil nozzle sub-assembly.

(d) Push the check valve while covering (A), and blow air into (B). Check that air passes through (C). Perform the check again while covering (B), pushing the check valve and blowing air into (A).

HINT:

If air does not pass through (C), clean or replace the No. 1 oil nozzle sub-assembly.

(a) Using a 5 mm hexagon socket wrench, install the 3 No. 1 oil nozzle sub-assemblies to the cylinder block sub-assembly with the 3 bolts.

Torque:

9.0 N·m {92 kgf·cm, 80 in·lbf}

(b) Gradually heat the piston to approximately 80°C (176°F).

(d) Align the front marks of the piston and connecting rod sub-assembly, and push in the piston pin with your thumb.

HINT:

The piston and piston pin are a matched set.

(e) Using a screwdriver, install a new piston pin hole snap ring at the other end of the piston pin hole.

NOTICE:

Make sure that the end gap of the piston pin hole snap ring is not aligned with the cutout of the piston pin hole.

(f) Check the fitting condition between the piston and piston pin.

(1) Move the connecting rod back and forth on the piston pin. Check the fitting condition.

HINT:

If abnormal movement is felt, replace the piston and piston pin as a set.

(2) Rotate the piston back and forth on the piston pin. Check the fitting condition.

HINT:

• If abnormal movement is felt, replace the piston and piston pin as a set.
• Perform Inspection After Repair after replacing the piston.

  Click here

(b) Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring as shown in the illustration.

NOTICE:

• Install the No. 1 compression ring with the code mark (T1) facing upward.
• Install the No. 2 compression ring with the code mark (T2) facing upward.

(c) Position the piston ring set so that the ring ends are as shown in the illustration.

NOTICE:

Do not align the ring ends.

HINT:

Perform Inspection After Repair after replacing the piston ring.

Click here

(a) Clean the main journals and both surfaces of the crankshaft bearings.

NOTICE:

Crankshaft bearings come in widths of 17.9 mm (0.705 in.) and 20.9 mm (0.823 in.). Install the 20.9 mm (0.823 in.) crankshaft bearings to the No. 1 and No. 4 cylinder block journal positions. Install the 17.9 mm (0.705 in.) crankshaft bearings to the No. 2 and No. 3 positions.

(b) Install the upper crankshaft bearings.

(1) Install the upper crankshaft bearings to the cylinder block sub-assembly as shown in the illustration.

NOTICE:

• Do not apply engine oil to the crankshaft bearings or the contact surfaces.
• Both sides of the oil groove in the cylinder block sub-assembly should be visible through the oil feed holes in the crankshaft bearing. The amount visible on each side of the holes should be equal.
• Do not allow coolant to come into contact with the crankshaft bearing inner surface.
• If any coolant comes into contact with the crankshaft bearing inner surface, replace the crankshaft bearing with a new one.

(c) Install the lower crankshaft bearings.

(1) Install the lower crankshaft bearings to the crankshaft bearing caps.

(2) Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and lower crankshaft bearing edge.

Difference Between (A) and (B):

0.7 mm (0.0276 in.) or less

NOTICE:

• Do not apply engine oil to the crankshaft bearings or the contact surfaces.
• Do not allow coolant to come into contact with the crankshaft bearing inner surface.
• If any coolant comes into contact with the crankshaft bearing inner surface, replace the crankshaft bearing with a new one.

(b) Install the crankshaft thrust washer set under the No. 2 journal position of the cylinder block sub-assembly with the oil grooves facing outward.

(b) Confirm the projections and numbers of the crankshaft bearing caps and install the 4 crankshaft bearing caps to the cylinder block sub-assembly.

HINT:

A number is marked on each crankshaft bearing cap to indicate its installation position.

(d) Temporarily install the 8 crankshaft bearing cap set bolts to the inside positions.

Bolt Length:

100 to 102 mm (3.94 to 4.02 in.)

(f) Using a plastic hammer, lightly tap the crankshaft bearing cap to ensure a proper fit.

(h) Temporarily install the 8 crankshaft bearing cap set bolts to the outside positions.

Bolt Length:

105.5 to 107.5 mm (4.15 to 4.23 in.)

(1) Uniformly tighten the 16 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

Torque:

61 N·m {622 kgf·cm, 45 ft·lbf}

HINT:

If a crankshaft bearing cap bolt cannot be tightened to the specified torque, replace it.

*a

Paint Mark

*b

Turn 90°

Front of Engine

(l) Install 8 new seal washers and uniformly tighten the 8 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

Torque:

51.5 N·m {525 kgf·cm, 38 ft·lbf}

(b) Using a vernier caliper, measure the distance between the connecting rod sub-assembly, connecting rod cap edges and the connecting rod bearing edge.

Difference Between (A) and (B):

0.7 mm (0.0276 in.) or less

NOTICE:

Do not apply engine oil to the connecting rod bearings or the contact surfaces.

(b) Position the piston ring set so that the ring ends are as shown in the illustration.

NOTICE:

Do not align the ring ends.

*A

for Bank 1

*B

for Bank 2

*a

Front Mark

-

-

Front of Engine

-

-

*a

Front Mark

Front of Engine

(1) Alternately tighten the 2 connecting rod bolts in several steps.

Torque:

24.5 N·m {250 kgf·cm, 18 ft·lbf}

*a

Paint Mark

*b

Turn 90°

Front of Engine

*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.)

-

-

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.)

*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.)

(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.

(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.)