Engine Mechanical: Removal & Installation — Toyota MR2 W30 (1999-2007)

INSTALLATION

Note. Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets and oil seals with new ones.

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Scheme 154: INSTALLATION

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PLACE CYLINDER HEAD ON CYLINDER BLOCK Place a new cylinder head gasket on the cylinder block surface with the lot No. upward. NOTE: Be careful of the installation direction. Place the cylinder head gently in order not to damage the gasket with the bottom part of the head.
INSTALL CYLINDER HEAD BOLTS NOTE: The cylinder head bolts are tightened in 2 steps (steps b and d. If any cylinder head bolt is broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts and plate washers in several passes, in the sequence shown. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. Mark the front of the cylinder head bolt with paint. Retighten the cylinder head bolts 90° in the numerical order (Scheme 155) Check that the painted mark is not at a 90° angle to the front. Install the bolt holding the water bypass pipe to the cylinder head. Torque: 9 N.m (92 kgf.cm, 80 in.lbf) Connect the upper radiator hose to the water hose union. Connect the heater hose to the water hose union.
INSTALL CAMSHAFTS Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown. Install the bearing caps in their proper locations. NOTE: No. 3 camshaft bearing cap has a number and front mark. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Install and uniformly tighten the 19 bearing cap bolts. After tightening the No. 1 camshaft bearing cap, tighten them in several passes, in the sequence shown. Torque: 23 N.m (235 kgf.cm, 17 ft.lbf) for No. 1 13 N.m (133 kgf.cm, 10 ft.lbf) for No. 3
CHECK AND ADJUST VALVE CLEARANCE. See «ADJUSTMENT»(ref-163243-S31163045222005030400000).
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE. See «CAMSHAFT TIMING OIL CONTROL VALVE»(ref-133226-S07399530522002021900000).
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE FILTER. See «CAMSHAFT TIMING OIL CONTROL VALVE»(ref-133226-S07399530522002021900000).
INSTALL CAMSHAFT TIMING SPROCKET AND VVT TIMING SPROCKET. See «INSTALLATION»(ref-163243-S38459488852005030400000).
INSTALL TIMING CHAIN. See step 4 under INSTALLATION.
INSTALL CAMSHAFT POSITION SENSOR. «CAMSHAFT POSITION SENSOR»(ref-172849-S26994927332005030400000)
INSTALL OIL FILLER CAP
INSTALL INTAKE MANIFOLD AND THROTTLE BODY ASSEMBLY Install a new gasket to the intake manifold. Install the intake manifold and throttle body assembly with the 2 brackets, 4 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 30 N.m (306 kgf.cm, 22 ft.lbf) Connect the 2 vacuum hoses to the intake manifold. Connect the 2 water hoses to the throttle body.
INSTALL PCV VALVE AND HOSES Install the PCV valve with the grommet. Install the PCV hoses.
CONNECT ENGINE WIRE Install the engine wire with the 2 bolts. Install the 2 ground straps with the 2 bolts. Connect the noise filter. Connect the throttle position sensor connector. SMT: Throttle control motor connector. SMT Accelerator position sensor connector. Connect the IAC valve connector. Connect the ECT sensor connector. Connect the camshaft position sensor connector. Connect the oil pressure switch connector and wire. Connect the knock sensor connector. Connect the crankshaft position sensor connector. Connect the camshaft timing oil control valve connector. Connect the heated oxygen sensor (bank 1 sensor 1) wire to the wire bracket.
INSTALL EXHAUST MANIFOLD Install a new gasket and the exhaust manifold with the 5 nuts. Torque: 37 N.m (377 kgf.cm, 27 ft.lbf) Install the 2 exhaust manifold stays with the 4 bolts. Torque: 37 N.m (377 kgf.cm, 27 ft.lbf) Place the upper heat insulator on the exhaust manifold. Install the 2 heated oxygen sensors. Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) Install the upper heat insulator with the 4 bolts. Connect the 2 heated oxygen sensors.
INSTALL INJECTORS. See «INSTALLATION»(ref-133226-S38953279982002021900000).
INSTALL SPARK PLUGS. See «IGNITION SYSTEM»(ref-172849-S02931458152005030400000).
INSTALL IGNITION COILS. See «IGNITION COIL»(ref-172849-S33165781032005030400000).
INSTALL GENERATOR. See «INSTALLATION»(ref-173147-S37754241662005031000000).
INSTALL ENGINE UNIT. See «INSTALLATION»(ref-163243-S06875620992005030400000).

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Scheme 165: COMPONENTS

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Scheme 170: REMOVAL

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REMOVE ENGINE HOOD.
REMOVE REAR SUSPENSION UPPER BRACE.
REMOVE ENGINE UNDER COVERS.
SMT: REDUCE ACCUMULATOR PRESSURE.
DRAIN ENGINE COOLANT.
DRAIN ENGINE OIL.
DRAIN TRANSAXLE OIL.
REMOVE BATTERY BRACKET. Remove the battery and tray. Disconnect the battery wire from the battery bracket. Remove the 3 bolts and battery bracket.
REMOVE INTAKE AIR HOSE AND AIR CLEANER CAP ASSEMBLY Disconnect the MAF meter connector, VSV connector for EVAP and VSV connector for CCV. Disconnect the 4 vacuum hoses. Disconnect the 2 clamps and air cleaner cap. Loosen the hose clamp, and remove the intake air hose and air cleaner cap assembly from the throttle body. Remove the air filter. Remove the 2 bolts and air cleaner lower case.
DISCONNECT ACCELERATOR CABLE
REMOVE REAR BUMPER COVER. (Scheme 165)
REMOVE FRONT EXHAUST PIPE Disconnect the heated oxygen sensor (bank 1 sensor 2) connector. Remove the 2 bolts, 2 springs and 3 nuts. Disconnect the ring, and remove the front exhaust pipe and 3 gaskets.
DISCONNECT A/C COMPRESSOR Remove the drive belt. Disconnect the A/C compressor connector. Remove the 3 bolts, and disconnect the A/C compressor. Suspend the A/C compressor securely.
DISCONNECT ENGINE WIRE Disconnect the engine wire from the luggage compartment. Remove the luggage compartment box. (Scheme 166) Disconnect the 2 ECM connectors. Disconnect the 4 junction connectors. Disconnect the grommet, and pull out the engine wire. SMT: Disconnect the transmission control ECU connector. Disconnect the engine wire from the J/B No. 1. Remove the relay box cover. Remove the nut, and disconnect the engine wire. Remove the 2 bolts, and disconnect the 2 ground wires. Separate the positive (+) battery wires. Remove the terminal cover. Remove the nut and terminal, and separate the battery wires. Disconnect the battery wire from the vehicle. Disconnect the 3 wire brackets and heated oxygen sensor (bank 1 sensor 2) wire from the vehicle.
DISCONNECT WATER HOSES Disconnect the 2 radiator hoses and 2 heater hoses.
SMT: DISCONNECT HPU CONNECTOR AND SMT SYSTEM HOSES. See «HYDRAULIC POWER UNIT»(ref-154683-S31739801452003052200000).
DISCONNECT FUEL TUBE Remove the fuel pipe clamp, and disconnect the fuel tube from the fuel pipe.
M/T: DISCONNECT CLUTCH HOSE. See «REMOVAL & INSTALLATION»(ref-154802-S42852931192003052700000).
M/T: DISCONNECT TRANSAXLE CONTROL CABLES. See «REMOVAL & INSTALLATION»(ref-154802-S42852931192003052700000).
REMOVE DRIVE SHAFTS. See «REMOVAL»(ref-163313-S30309507062004062500000).
SET ENGINE JACK Remove the 2 clips, 2 nuts and No. 2 cylinder head cover, and set a engine jack. NOTE: Using chain, hold the engine tightly.
DISCONNECT ENGINE MOUNTING Remove the through bolt and nut holding the LH engine mounting insulator to the mounting bracket. Remove the 3 bolts, 3 nuts and RH engine mounting insulator. Remove the through bolt and nut holding the front engine mounting insulator to the mounting bracket.
REMOVE SUSPENSION MEMBER Remove the 2 bolts, and disconnect the ABS wire. M/T: Remove the 4 bolts, and disconnect the suspension member. SMT: Remove the 4 bolts, and disconnect the suspension member and HPU assembly. Remove the through bolt, nut and suspension member.
REMOVE ENGINE AND TRANSAXLE ASSEMBLY Lower the engine out of vehicle slowly and carefully. NOTE: Make sure the engine is clear of all wiring, hoses and cables. Using a engine sliding device, and place the engine and transaxle assembly onto the stand.
SEPARATE ENGINE AND TRANSAXLE. See «REMOVAL & INSTALLATION»(ref-154802-S42852931192003052700000). Remove the starter. See «REMOVAL & INSTALLATION»(ref-139867-S41464998922002051000000). Remove the 6 bolts, and separate the engine and transaxle.
REMOVE CLUTCH DISC. See «CLUTCH ASSEMBLY»(ref-154802-S01775733832003052700000).
REMOVE FLYWHEEL Remove the 8 bolts and flywheel.

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Scheme 189: INSTALLATION

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INSTALL FLYWHEEL NOTE: The mounting bolts are tightened in steps ( c ) and ( e ). If any one of the mounting bolts is broken or deformed, replace it. Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Install the flywheel on the crankshaft. Install and uniformly tighten the 8 bolts in several passes, in the sequence shown. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) If any one of the bolts does not meet the torque specification, replace the bolt. Mark the flywheel bolt with paint. Retighten the flywheel bolts by an additional 90 degrees.
INSTALL CLUTCH DISC AND COVER. See «CLUTCH ASSEMBLY»(ref-154802-S01775733832003052700000).
INSTALL TRANSAXLE TO ENGINE. See «REMOVAL & INSTALLATION»(ref-154802-S42852931192003052700000). Attach the transaxle to the engine, and install the 6 bolts. Install the starter See «REMOVAL & INSTALLATION»(ref-139867-S41464998922002051000000).
SET ENGINE JACK NOTE: Using a chain, hold the engine tightly.
INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE Raise the engine into the engine compartment. M/T: Temporarily install the rear suspension member to the engine with the through bolt and nut. SMT: Temporarily install the rear suspension member and HPU assembly to the engine with the through bolt and nut. Connect the rear suspension member with the 4 bolts. Torque: 80 N.m (816 kgf.cm, 59 ft.lbf) Connect the ABS wire with the 2 bolts. Install the RH engine mounting insulator with the 3 bolts and 3 nuts. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) Temporarily install the through bolt and nut holding the LH engine mounting insulator to the mounting bracket. Tighten the through bolt and nut holding the rear engine mounting insulator to the mounting bracket. Torque: 93 N.m (948 kgf.cm, 69 ft.lbf) NOTE: Be sure to tighten the bolt at the upper end of slot. Install the through bolt holding the front engine mounting insulator to the mounting bracket. Torque: 93 N.m (950 kgf.cm, 69 ft.lbf) Tighten the through bolt and nut holding the LH engine mounting insulator to the mounting bracket. Torque: 87 N.m (887 kgf.cm, 64 ft.lbf) Remove the engine jack, and install the No. 2 cylinder head cover with the 2 clips and 2 nuts.
INSTALL DRIVE SHAFTS. See «INSTALLATION»(ref-163313-S40494622642004062500000).
M/T: CONNECT TRANSAXLE CONTROL CABLES. See «REMOVAL & INSTALLATION»(ref-154802-S42852931192003052700000).
M/T: CONNECT CLUTCH HOSE. See «REMOVAL & INSTALLATION»(ref-154802-S42852931192003052700000).
CONNECT FUEL TUBE Connect the fuel tube to the fuel pipe, and install the fuel pipe clamp.
CONNECT HPU CONNECTOR AND SMT SYSTEM HOSES. See «HYDRAULIC POWER UNIT»(ref-154683-S31739801452003052200000).
CONNECT WATER HOSES Connect the 2 radiator hoses and 2 heater hoses.
CONNECT ENGINE WIRE Connect the 3 wire brackets and heated oxygen sensor (bank 1 sensor 2) wire to the vehicle. Assemble the positive (+) battery wires. Assemble the battery wires, and install the terminal with the nut. Install the terminal cover. Connect the 2 ground wires with the 2 bolts. Connect the engine wire to the J/B No. 1. Connect the engine wire with the nut. Install the relay box cover. SMT: Connect the transmission control ECU connector. Connect the engine wire to the luggage compartment. Pull in the engine wire to the luggage compartment, and connect the grommet. Connect the 4 junction connectors. Connect the 2 ECM connectors. Install the luggage compartment box. (Scheme 166)
INSTALL A/C COMPRESSOR Install the A/C compressor with the 3 bolts. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) Connect the A/C compressor connector. Install the drive belt.
INSTALL FRONT EXHAUST PIPE Connect the ring. Install 3 new gaskets and the front exhaust pipe with the 2 bolts, 2 springs and 3 nuts. Torque: 43 N.m (438 kgf.cm, 32 ft.lbf) for bolt 62 N.m (632 kgf.cm, 46 ft.lbf) for nut Connect the heated oxygen sensor (bank 2 sensor 1) connector.
INSTALL REAR BUMPER COVER AND REAR COMBINATION LIGHTS. (Scheme 165)
CONNECT ACCELERATOR CABLE Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)
INSTALL INTAKE AIR HOSE AND AIR CLEANER CAP ASSEMBLY Install the air cleaner lower case with the 2 bolts. Install the air filter. Install the intake air hose and air cleaner cap assembly to the throttle body, and tighten the hose clamp. Connect the air cleaner cap with the 2 clamps. Connect the 4 hoses. Connect the MAF meter connector, VSV connector for EVAP and VSV connector for CCV.
INSTALL BATTERY BRACKET Install the battery bracket with the 3 bolts. NOTE: Install bolt A with the air cleaner case. Install the tray and battery.
M/T: FILL CLUTCH RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM
M/T: FILL WITH TRANSAXLE OIL. See «RECOMMENDED FLUIDS»(ref-154683-S07047159472003052200000).
SMT: FILL WITH TRANSMISSION OIL. See «RECOMMENDED FLUIDS»(ref-154683-S07047159472003052200000).
FILL WITH ENGINE OIL
SMT: CHECK SMT SYSTEM FLUID LEVEL. See «GEARSHIFT ACTUATOR ASSEMBLY (SEQUENTIAL TRANSAXLE»(ref-154683-S15112760432002083000000).
FILL WITH ENGINE COOLANT. See «COOLANT»(ref-172848-S12562313892005030400000).
SMT: START ENGINE AND PERFORM INITIAL LEARNING OF SMT SYSTEM. See «PROGRAMMING»(ref-154148-S10329731992003050800000).
CHECK FOR LEAK
PERFORM ENGINE ADJUSTMENT
CHECK FRONT WHEEL ALIGNMENT
INSTALL ENGINE UNDER COVERS
INSTALL SUSPENSION UPPER BRACE
INSTALL ENGINE HOOD
ROAD TEST VEHICLE Check for abnormal noises, shock slippage, correct shift points and smooth operation.
RECHECK ENGINE COOLANT AND OIL LEVELS

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Scheme 212: COMPONENTS

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Scheme 214: DISASSEMBLY

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INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY
REMOVE CYLINDER HEAD . See «REMOVAL»(ref-163243-S05360173592005030400000) .
REMOVE WATER BYPASS PIPE Remove the 2 nuts, bolts, water bypass pipe and gasket.
REMOVE THERMOSTAT . See «REMOVAL»(ref-172848-S15734471062005030400000) .
REMOVE KNOCK SENSOR
REMOVE ENGINE COOLANT DRAIN UNION
REMOVE OIL PUMP . See «REMOVAL»(ref-172852-S22912986462005030700000) .
REMOVE OIL FILTER . See «REPLACEMENT»(ref-172852-S25876557552005030700000) .
REMOVE OIL FILTER UNION Using a 12 mm hexagon wrench, remove the oil filter union.
REMOVE OIL PAN Remove the 14 bolts and 2 nuts. Insert the blade of SST between the bearing cap subassembly and oil pan, and cut off applied sealer and remove the oil pan. SST 09032-00100 NOTE: Be careful not to the damage the oil pan contact surface of the bearing cap subassembly. Be careful not to damage the oil pan flange.
REMOVE OIL STRAINER Remove the 2 nuts, bolt, oil strainer and gasket.
CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.160 - 0.342 mm (0.0063 - 0.0135 in.) Maximum thrust clearance: 0.342 mm (0.0135 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. Connecting rod thickness: 19.788 - 19.840 mm (0.7791 - 0.7811 in.)
REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly. Remove the 2 connecting rod cap bolts. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. NOTE: Keep the lower bearing inserted with the connecting rod cap. Clean the crank pin and bearing. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. Lay a strip of Plastigage on the crank pin. Install the connecting rod cap with the 2 bolts. See step 13 under REASSEMBLY. NOTE: Do not turn the crankshaft. Remove the 2 bolts, connecting rod cap and lower bearing. See procedure steps b and c above). Measure the Plastigage at its widest point. Standard oil clearance: 0.028 - 0.060 mm (0.0011 - 0.0024 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. NOTE: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly. Standard bearing center wall thickness: Completely remove the Plastigage.
REMOVE PISTON AND CONNECTING ROD ASSEMBLIES Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. NOTE: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.
REMOVE BEARING CAP SUBASSEMBLY AND CRANKSHAFT REAR OIL SEAL, AND CHECK OIL CLEARANCE Remove the 10 hexagon head bearing cap bolts. Uniformly loosen and remove the 10 bearing cap bolts in several passes, in the sequence shown. Using a screwdriver, remove the bearing cap subassembly by prying the portions between the cylinder block and bearing cap subassembly. Remove the 5 lower main bearings. NOTE: Be careful not to damage the contact surfaces of the cylinder block and bearing cap subassembly. NOTE: Keep the lower bearing and bearing cap subassembly together. Remove the crankshaft rear oil seal. Lift out the crankshaft. NOTE: Keep the upper bearings together with the cylinder block. Clean each main journal and bearing. Check each main journal, bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. Install the bearing cap subassembly. See step 7 under REASSEMBLY. NOTE: Do not turn the crankshaft. Remove the bearing cap subassembly. See procedures a to d above. Measure the Plastigage at its widest point. Standard oil clearance: 0.015 - 0.032 mm (0.0006 - 0.0013 in.) Maximum oil clearance: 0.050 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then selecting the bearing with the same number as the total. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly. EXAMPLE: Cylinder block "4" (A) + Crankshaft "3" (B) = Total number 7 (Use bearing "3") Standard bearings selection chart EXAMPLE: Cylinder block "4", Crank shaft "3", Use bearing "3" Reference Completely remove the Plastigage.
CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04 - 0.24 mm (0.0016 - 0.0094 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the thrust washers as a set. Thrust washer thickness: 2.430 - 2.480 mm (0.0957 - 0.0976 in.)
REMOVE CRANKSHAFT Lift out the crankshaft. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block. HINT: Arrange the main bearings and thrust washers in the correct order.
CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
REMOVE PISTON RINGS Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand. NOTE: Arrange the piston rings in the correct order only.
DISCONNECT CONNECTING ROD FROM PISTON Using a small screwdriver, pry out the 2 snap rings. Gradually heat the piston to 80 - 90°C (176 - 194°F). Using a plastic-faced hammer and a brass bar, lightly tap out the piston pin and remove the connecting rod. NOTE: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

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Scheme 243: INSPECTION

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CLEAN CYLINDER BLOCK Remove the gasket material. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. Clean the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block. NOTE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at a temperature of 45°C (133°F) or less.
INSPECT CYLINDER BLOCK Inspect for flatness. Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) If warpage is greater than maximum, replace the cylinder block. Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block. Inspect the cylinder bore diameter. Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: 79.000 - 79.013 mm (3.1102 - 3.1107 in.) Maximum diameter: 79.013 mm (3.1107 in.) If the diameter is greater than maximum, replace the cylinder block.
REMOVE CYLINDER RIDGE If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.
INSPECT 12 POINTED HEAD BEARING CAP SUBASSEMBLY BOLTS Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.3 - 7.5 mm (0.287 - 0.295 in.) Minimum diameter: 7.3 mm (0.287 in.) If the diameter is less than minimum, replace the bolt.
CLEAN PISTON Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool or a broken ring, clean the piston ring grooves. Using a brush and solvent, thoroughly clean the piston. NOTE: Do not use a wire brush.
INSPECT PISTON Inspect the piston oil clearance. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 25.6 mm (1.008 in.) from the piston head. Piston diameter: 78.925 - 78.935 mm (3.1073 - 3.1077 in.) Measure the cylinder bore diameter in the thrust directions (See step 2 ). Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.065 - 0.088 mm (0.0026 - 0.0035 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder block. Inspect the piston ring groove clearance. Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Ring groove clearance: 0.020 - 0.070 mm (0.0008 - 0.0028 in.) If the clearance is not as specified, replace the piston. Inspect the piston ring end gap. Insert the piston ring into the cylinder bore. Using the piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. Using a feeler gauge, measure the end gap. If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block. Inspect the piston pin fit. At 80 - 90°C (176 - 194°F), you should be able to push the piston pin into the piston pin hole with your thumb.
INSPECT CONNECTING ROD Using a rod aligner and a feeler gauge, check the connecting rod alignment. Check for out-of-alignment. Maximum out-of-alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If out-of-alignment is greater than maximum, replace the connecting rod assembly. Check for twist. Maximum twist: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connecting rod assembly. Inspect the piston pin oil clearance. Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 20.012 - 20.021 mm (0.7879 - 0.7882 in.) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 20.004 - 20.013 mm (0.7876 - 0.7879 in.) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the bushing. See «REPLACEMENT»(ref-163243-S40975664182005030400000). If necessary, replace the piston and piston pin as a set.
INSPECT CONNECTING ROD BOLTS Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 6.6 - 6.7 mm (0.260 - 0.264 in.) Minimum diameter: 6.4 mm (0.252 in.) If the diameter is less than minimum, replace the bolt.
INSPECT CRANKSHAFT Inspect for circle runout. Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than maximum, replace the crankshaft. Inspect the main journals and crank pins. Using a micrometer, measure the diameter of each main journal and crank pin. Diameter: Main Journal: 47.988-48.000 mm (1.8893-1.8898 in.) Crank Pin: 43.992-44.000 mm (1.7320-1.7323 in.) If the diameter is not as specified, check the oil clearance. See «DISASSEMBLY»(ref-163243-S02887122932005030400000). If necessary, replace the crankshaft. Check each main journal and crank pin for taper and out-of-round (Scheme 265) Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of-round is greater than maximum, replace the crankshaft.

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Scheme 266: REPLACEMENT

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REPLACE CONNECTING ROD BUSHINGS Using SST and a press, press out the bushing. SST 09222-30010 Align the oil hoses of a new bushing and the connecting rod. Using SST and a press, press in the bushing. SST 09222-30010 Using a pin hole grinder, hone the bushing to obtain the standard specified clearance between the bushing and piston pin. See «INSPECTION»(ref-163243-S01700834802005030400000) . Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
REPLACE CRANKSHAFT REAR OIL SEAL If the rear oil seal is installed to the cylinder block. Using a knife, cut off the oil seal lip. Using a screwdriver, pry out the oil seal. NOTE: Be careful not to damage the crankshaft. Tape the screwdriver tip. Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100)

Engine Mechanical: Removal & Installation Toyota MR2 W30