Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

SYS.OK|MANUAL.DB● LIVE

HOMESERVICE MANUALSTOYOTA2004MATRIX XR, FWD, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 644 (ENGINE MECHANICAL (2AZ-FE))CYLINDER BLOCK ASSEMBLYOVERHAUL

2004 Toyota Matrix XR, FWD, Standard

Cylinder Block Assembly: Overhaul

2004 Toyota Matrix XR, FWD, StandardSECTION Overhaul

WARNING: This page is about a different car, the 2004 Toyota Camry. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT CONNECTING ROD THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Specified thrust clearance:

0.160 to 0.362 mm (0.0063 to 0.0143 in.)

If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.

Fig 1: Measuring Thrust Clearance Of Connecting Rod
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CONNECTING ROD OIL CLEARANCE

HINT:

The connecting rod cap bolts are tightened in 2 progressive steps.

Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly.
HINT:

The matchmarks on the connecting rods and caps are for ensuring the 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.
HINT:

Fig 2: Identifying Connecting Rod Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Keep the lower bearing inserted to the connecting rod cap.
Clean the crank pin and bearing.
Check the crank pin and bearing for pitting and scratches.

Fig 3: Installing A Strip Of Plastigage On Crank Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Lay a strip of Plastigage on the crank pin.
Check that the front mark of the connecting rod cap is facing in the correct direction.
Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
Install the connecting cap (see step 37).
NOTE: Do not turn the crankshaft.
Remove the 2 bolts and connecting rod cap.

Fig 4: Identifying Front Mark Of Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Measure the Plastigage at its widest point.

Specified oil clearance:

0.024 to 0.080 mm (0.0009 to 0.0031 in.)

If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

Fig 5: Measuring Plastigage

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

If replacing a bearing, replace it with one that has the same number as the connecting rod. There are 3 sizes of standard bearings: 1, 2 and 3.

Standard bearing center wall thickness:

STANDARD BEARING CENTER WALL THICKNESS

Mark 1	1.485 to 1.488 mm (0.0585 to 0.0586 in.)
Mark 2	1.488 to 1.491 mm (0.0586 to 0.0587 in.)
Mark 3	1.491 to 1.494 mm (0.0587 to 0.0588 in.)

Completely remove the Plastigage.

Fig 6: Identifying Location Of Marks On Bearing Cap & Bearing Shell
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE PISTON SUB-ASSEMBLY W/CONNECTING ROD
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
HINT:
- Keep the bearing, connecting rod and cap together.
- Arrange the piston and connecting rod assemblies in the correct order.
  
  Fig 7: Using Ridge Reamer To Remove Carbon From Top Of Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONNECTING ROD BEARING
REMOVE PISTON RING SET
1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the 2 side rails and oil ring by hand.
  
  Fig 8: Removing Compression Rings From Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON PIN HOLE SNAP RING
1. Using a small screwdriver, pry out the 2 snap rings.
  
  Fig 9: Removing Snap Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PISTON
1. Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).
  
  Fig 10: Heating-up Pistons
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.
HINT:
- The piston and pin are a matched set.
- Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
  
  Fig 11: Removing Piston Pin & Connecting Rod From Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
  Specified thrust clearance:
  
  0.040 to 0.300 mm (0.0016 to 0.0118 in.)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set.

Thrust washer thickness:

1.930 to 1.980 mm (0.0760 to 0.0780 in.)

Fig 12: Measuring Thrust Clearance of Crankshaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT OIL CLEARANCE
1. Uniformly loosen and remove the 10 main bearing cap bolts, in the sequence shown.
  
  Fig 13: Removing Main Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Use 2 removed main bearing cap bolts to remove the 5 main bearing caps and 5 lower bearings.
  NOTE: Insert the bolts into one of the caps. Ease the cap out by gently pulling up and applying force toward the front and back side of the cylinder block, as shown. Take care not to damage the contact surfaces of the cap and cylinder block.
  
  HINT:
  
  Fig 14: Using 2 Main Bearing Cap Bolts To Remove Main Bearing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Keep the lower bearing and main bearing cap together.
  - Arrange the main bearing caps in correct order.
3. Lift out the crankshaft.
  HINT:
  
  Keep the upper bearings together with the cylinder block.
4. Clean each main journal and bearing.
5. Check each main journal and bearing for pitting and scratches.
  If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
6. Place the crankshaft on the cylinder block.
7. Lay a strip of Plastigage across each journal.
8. Install the main bearing caps (see step 36).
  HINT:
  
  Do not turn the crankshaft.
9. Remove the main bearing cap (see steps (a) and (b) above).
  
  Fig 15: Installing Plastigage Between Journal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Measure the Plastigage at its widest point.
  Standard oil clearance:
  
  0.008 to 0.024 mm (0.00031 to 0.00094 in.)
  
  If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.
  
  Fig 16: Measuring Plastigage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. 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, and then selecting the bearing according to the chart below. There are 4 sizes of standard bearings: 1, 2, 3, and 4.
  
  Fig 17: Bearing Size Chart
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002