V06_Dealer Packa

◄ IMPORTANT UPDATE ►
The attached Dealer Packet has been updated. Refer to the details below.
DATE
9/24/2018
TOPIC
A watermark has been added to the Dealer Packet to indicate that V06 SSC expired on
September 24, 2018.
Please review this notification with your staff to assure that all relevant personnel have been briefed regarding this
subject.
Thank you for your cooperation.
© 2018 Toyota Motor Sales, USA
TOYOTA
ALL TOYOTA DEALER PRINCIPALS,
SERVICE MANAGERS, PARTS MANAGERS
SUBJECT:
SPECIAL POLICY ADJUSTMENT FOR 1988 – EARLY 1990 TRUCK &
4RUNNER WITH 3VZ–E V6 ENGINES
AND
SPECIAL SERVICE CAMPAIGN (V06) FOR 1990 – EARLY 1995 TRUCK,
4RUNNER & T100 WITH 3VZ–E V6 ENGINES
3VZ–E Head Gasket Special Policy Adjustment
In October 1996, Toyota announced a Special Policy Adjustment that provided extended
warranty coverage for the head gaskets of certain 1988–1994 Toyota Compact Pickup
Truck, 4Runner, and T100 equipped with the 3VZ–E V6 engine. This Special Policy Adjustment extended the warranty coverage for the head gaskets to 8 years or 100,000 miles
(whichever occurred first) or 12 months from the date of the owner notification letter.
Commencing in Dec., 1997, Toyota will proceed with the Special Policy Adjustment
Warranty Extension program by notifying the remaining owners of 1988, 1989 and
early production (up to 12/89 production date) Toyota Compact Pick–up Truck and
4Runner equipped with 3VZ–E V6 engines who have not previously received any
notification or have not received any head gasket repairs from a Toyota dealer since
October 1, 1996.
Since introducing this Special Policy Adjustment, Toyota has identified that the
head gasket failure condition is primarily limited to a particular production period of
the involved vehicles. As a result, for a specific group of the vehicles previously
involved in the Special Policy Adjustment, Toyota is now changing the handling
procedure to a Special Service Campaign.
3VZ–E Head Gasket Special Service Campaign (V06)
With the introduction of the new Special Service Campaign(V06), owners of late
production 1990, all 1991, 1992, 1993, and 1994 up to early production 1995 (1/90 to
10/94 production date) Toyota Compact Pick–up Truck, 4Runner and T100 equipped
with 3VZ–E V6 engines who have not received any head gasket repairs from a
Toyota dealer since October 1, 1996 will be notified to contact a Toyota dealer for
head gaskets replacement.
Vehicle owners who have previously paid for head gasket replacement will be instructed to
call the National Customer Relations Department at 1–800–404–7636 to obtain further
directions.
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TO:
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Toyota Motor Sales, U.S.A., Inc.
19001 South Western Avenue
P.O. Box 2991
Torrance, CA 90509–2991
(310) 618–4000
(310) 618–7800 Fax
3VZ–E SPA/SSC—V06
Page 2
The following information is provided to inform you and your staff of the Special Policy
Adjustment/Special Service Campaign Program procedure and your degree of
involvement:
Special Policy Adjustment/Special Service Campaign Program Details
Special Service Campaign
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Special Policy Adjustment
Late 1990 through early 1995
Toyota Compact Pick–up
Truck, 4Runner and T100
vehicles. (See VIN range listing
for actual involved vehicles).
Who will be
notified?
Owners that have not been
previously notified or received
repairs since Oct. 1,1996.
Owners who have not previously
received repairs since Oct. 1,
1996.
What will Toyota
do?
Owners of the involved vehicles
under the Special Policy
Adjustment Program will be
provided a dated warranty
extension document to keep with
their vehicle owner’s guide. If a
head gasket fails within the 8
years or 100,000 miles extended
warranty period, or within 12
months from the date of the
owner notification letter, they can
contact any Toyota dealer to have
both head gaskets replaced at no
cost to them.
Under the Special Service
Campaign Program, the head
gaskets will be replaced on all the
affected vehicles regardless of
leakage or not, and there will not
be any age, mileage or time
restrictions under the Special
Service Campaign.
On the vehicles WHERE THE
HEAD GASKETS HAVE FAILED,
Toyota dealers will install new
head gaskets at no cost to the
owner. Other engine
components, damaged as a
result of a head gasket failure,
will also be eligible for repair or
replacement under this warranty.
Toyota dealers will install new
head gaskets at no cost to the
owner regardless of leakage or
not.
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Which 3VZ–E V6 1988 through early 1990 Toyota
equipped vehicles Compact Pick–up Truck and
are affected?
4Runner. (See VIN range listing
for actual involved vehicles).
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What will Toyota
dealers do?
Are all repairs at
no cost to the
customers?
When will owners
be notified?
Under both programs, the head gaskets and the related repairs
will be covered by Toyota. However, while the engine is
disassembled, it may also be advantageous for the customer to have
other maintenance and repairs performed. Please note that these
items are at customer expense as they are not related to the
durability of the head gasket.
Mailing will commence in Dec, 1997 and continue until all involved
vehicle owners are notified. The volume and frequency of mailings
will depend on parts supply and dealer repair capacity.
3VZ–E SPA/SSC—V06
Page 3
Please review this entire package with your Service and Parts staff to familiarize them with
the proper step–by–step procedure and implement this Special Policy Adjustment/Special
Service Campaign Program to ensure customer satisfaction.
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TOYOTA MOTOR SALES, U.S.A., INC.
Customer Services Division
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Thank you for your cooperation.
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SPECIAL POLICY ADJUSTMENT
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SPA Expired
3VZ–E HEAD GASKET SPA
Page 1
1.
Owner Notification Letters Mailing Date
Commencing in December, 1997 (Copy attached)
Identification of Involved Special Policy Adjustment Program Vehicles
Vehicle Model
1988 – 1989 4Runner
VDS
VIN Range
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2.
VN66W
VN62M
VN62N
0000001 – 0040703
VN63C
VN63M
VN64N
VN67M
VN67N
0000001 – 0040703
VN82D
VN82N
VN82R
VN82T
VN93D
VN93G
VN94T
0000001
5000001
0000001
5000001
0000001
5000001
0000001
VN01D
VN01G
0000001 – 0001355 and
2000001 – 2006626 and
6000001 – 6006342
1989 – 1990 Truck
4X4 Long Bed
VN02D
0000001 – 0000194 and
2000000 – 2001257 and
6000000 – 6002131
1989 – 1990 Truck
4X4 Xtracab
1990 4Runner
4X2
1990 4Runner
4X4
VN13D
VN13G
VN29V
0000001 – 0016346 and
5000001 – 5021512
0000001 – 0002751
VN39J
VN39W
0000001 – 0031089
1988 Truck
4X4 Std Bed
1988 Truck
4X4 Long Bed & Xtracab
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1989 – 1990 Truck
4X2 Long Bed & One Ton
1989 – 1990 Cab Chassis
Regular Wheelbase
1989 – 1990 Truck
4X2 Xtracab
1989 – 1990 Cab Chassis
Long Wheelbase
1989 – 1990 Truck
4X4 Std Bed
0000001 – 0011623
SPA Expired
– 0003070 and
– 5003062
– 0003070 and
– 5003062
– 0006118 and
– 5009265
– 0014059
3VZ–E Head Gasket SPA
Page 2
Technical Instructions and Guidelines for Special Policy Adjustment


Refer to the applicable repair manuals for repair procedures and specifications.


Replace both left and right head gaskets even if only one side is leaking.


Inspect cylinder heads and blocks for warpage and erosion per attached
instruction. Also see video tape previously released in February, 1997.


If the cylinder head or block mating surface is warped or eroded beyond service
specification, repair the heads and/or blocks by machining up to a combined
maximum of 0.25 mm (0.010 in) from the cylinder head mating surfaces. If the
warpage or erosion exceeds the maximum specification, the cylinder head or
short block assembly must be replaced.
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3.
PLEASE NOTE: DSM inspection and authorization is required if the short
block assembly is to be replaced. Refer to Policy No: 5.3 of the Warranty
Policy and Procedures Manual.


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Additional parts and fluids that are required as a result of performing the head
gasket replacement are also covered.
Parts Ordering
To avoid parts shortages, please observe the following guidelines for conservative parts ordering:


Stock only basic gaskets and non–reusable parts.


Order major parts only as required to repair failed vehicles.


Replenishment orders of gaskets and non–reusable parts should be based
on a “sell one, buy one” basis.


Parts ordering will be reviewed based on dealer’s submitted claims.
The cylinder head gasket kit as well as related necessary parts can be ordered from
your facing Parts Distribution Center.
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4.
PART NUMBER
DESCRIPTION
04007–02135
Cylinder Head Gasket Kit
SPA Expired
3VZ–E Head Gasket SPA
Page 3
Operation Flow Chart for Special Policy Adjustment
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5.
SPA Expired
3VZ–E Head Gasket SPA
Page 4
6.
Reimbursement Procedures
Submit warranty claims following the regular procedures described in the Toyota
Warranty Policy & Procedures Manual. The following operation codes are applicable
for:
Head gasket replacement within 8 years or 100,000 miles Special Policy
Adjustment, or


Head gasket replacement within 12 months after customer received dated
Warranty Extension document
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Please refer to the following VDS vs. Japan Model Code reference table to determine
the applicable flat rate time.
Model
VDS
Model
VN62N
VN62M
VN63C
VN63M
VN66W
VZN61
VN64N
VN67M
VN67N
VZN66
VN82D
VN82N
VN82R
VN82T
VN94T
VZN85
VN93D
VN93G
VZN90
VZN95
VZN100
VN02D
VZN105
VN29V
VZN120
VN01D
VN01G
VN13D
VN13G
VN39J
VN39W
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VDS
SPA Expired
VZN110
VZN130
SPA Expired
3VZ–E Head Gasket SPA
Page 5
FLAT RATE HOURS
VZN61
VZN66
1 110051 R&R HEAD GASKET
Varied Work Code N
Comb Code A=Opposite side
Comb Code Z =Opposite side
Comb Code L=A/C
Comb Code Z=Extra diagnostic time required
for SPA procedures
2 110011 R&R CYLINDER HEAD
VZN100
VZN105
VZN110
VZN130
8.5
6.6
6.6
–
2.0
2.0
2.0
–
–
–
0.4
0.4
–
2.0
2.0
14.3
10.4
10.4
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Varied Work Code N
VZN85
VZN90
VZN95
VZN120
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SPA–3VZ–E
Operation Code
Comb Code A=Opposite cylinder head
–
4.0
4.0
Comb Code Z=Opposite cylinder head
5.8
–
–
Comb Code Z=Opposite head gasket
2.0
2.0
2.0
Comb Code L=A/C
–
0.4
0.4
Comb Code Z=Extra diagnostic time required
for SPA procedures
–
5.8
5.8
Varied Work Code N
18.1
16.3
18.2
Comb Code C=A/C
0.4
–
–
Comb Code K=A/C
–
0.4
0.4
2.0
2.0
2.0
4.0
4.0
4.0
Varied Work Code N
16.3
14.5
16.4
Comb Code C=A/C
0.4
–
–
Comb Code K=A/C
–
0.4
0.4
Comb Code Z=Replace one head
2.0
–
–
Comb Code C=Replace one head
–
2.0
2.0
4.0
–
–
–
4.0
4.0
22.0
22.0
22.0
3 111011 R&R CYLINDER BLOCK
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Comb Code Z=Replace one head
Comb Code Z=Replace both heads
4 120101 R&R SHORT BLOCK
Comb Code Z=Replace both heads
Comb Code CC=Replace both heads
5 EN7001 RESURFACE BLOCK
3VZ–E Head Gasket SPA
Page 6
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Claim Submission:
Use Claim Type = “RG”
DSM authorization is required if the cylinder or short block is replaced.
T1 = 64 (Leaks)
T2 = 13 (Deformed –bent, twisted, warped, shrunk, wrinkled)
OPN = 11115–XXXXX
Enter actual cost in sublet column using the following sublet types:
Rental
= “ZZ”
Fluids
= “OF”
Machining
= “MC”
Towing
= “TW”
Enter CCR describing actual repair performed.
Rental Allowance:
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Rentals for the SPA should be submitted on the repair claim using sublet type
“ZZ.” The rental guideline is a maximum 3 days at $30.00 per day. If the
rental is required for more than three days, or costs more than $30.00 per
day then DSM authorization is required on the claim. The rental should not
be submitted on a separate claim.
SPA Expired
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SPA Expired
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SPA Expired
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SPECIAL SERVICE CAMPAIGN
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V06
3VZ–E Head Gasket SSC—V06
Page 1
1.
Owner Notification Letters Mailing Date
Commencing in December, 1997 (copy attached)
Identification of Involved Special Service Campaign Program Vehicles
Vehicle Model
VIN Range
VN82D
VN82N
VN82R
VN82T
VN93D
VN93G
VN94T
0003071
5003063
0003071
5003063
5009266
1990 – 1992 Truck
4X4 Long Bed
1990 – 1995 Truck
4X4 Xtracab
1990 – 1995 4Runner
4X2
1990 – 1995 4Runner
4X4
1993 – 1995 T100 4X2
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1993 – 1995 T100 4X4
– 0004067 and
– 5005247
– 0004067 and
– 5005247
– 5044036
VN01D
VN01G
0001356 – 0006877 and
2006627 – 2015028 and
Z000001 – Z311415
0014060 – 0032901
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1990 – 1992 Truck
4X2 Long Bed & One Ton
1990 – 1993 Cab Chassis
Regular Wheelbase
1990 – 1995 Truck
4X2 Xtracab
1990 – 1993 Cab Chassis
Long Wheelbase
1990 – 1995 Truck
4X4 Std Bed
VDS
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2.
VN02D
2001258 – 2002582
VN13D
VN13G
VN29V
5021513 – 5151019 and
Z000001 – Z311529
0002752 – 0043478 and
9000000 – 9000904
0031090 – 0180701 and
8000000 – 8076027
0000001 – 0023886
VN39J
VN39W
VD10A
VD10B
VD10C
VD20A
VD20C
0000001 – 0015886
3VZ–E Head Gasket SSC—V06
Page 2
Technical Instructions and Guidelines


Refer to the applicable repair manuals for repair procedures and specifications.


If there are signs of head gasket leakage, inspect cylinder heads and blocks for
warpage and erosion per attached instruction. Also refer to video previously
released in February, 1997.


If the cylinder head or block mating surface is warped or eroded beyond service
specification, repair the heads and/or blocks by machining up to a combined
maximum of 0.25 mm (0.010 in) from the cylinder head mating surfaces. If the
warpage or erosion exceeds the maximum specification, the cylinder head or
short block assembly must be replaced.
ED
3.
PLEASE NOTE: DSM inspection and authorization is required if the short
block assembly is to be replaced. Refer to Policy No: 5.3 of the Warranty
Policy and Procedures Manual.
Additional parts and fluids that are required as a result of performing the head
gasket replacement are also covered.
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3VZ–E Head Gasket SSC—V06
Page 3
Operation Flow Chart for Special Service Campaign
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4.
3VZ–E Head Gasket SSC—V06
Page 4
5.
Parts Ordering
The supply of parts for this Special Service Campaign is extremely critical. To
avoid parts shortage please observe the following guidelines for conservative
parts ordering:
A specific PMA dealer/owner list for each individual mailing will be provided to each dealer before any owner notifications are launched. Dealer’s
parts order should not exceed 10% of the involved vehicles on the list.


Replenishment orders of gaskets and non–reusable parts should be based
on a “sell one, buy one” basis.


Parts ordering will be reviewed based on dealer’s submitted claims.
ED


The cylinder head gasket kit as well as related necessary parts can be ordered from
your facing Parts Distribution Center.
PART NUMBER
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DESCRIPTION
04007–02135
Reimbursement Procedures
Submit warranty claims following the regular procedures described in the Toyota
Warranty Policy & Procedures Manual. The following operation codes are applicable
for: Head gasket replacement under Special Service Campaign.
Please refer to the following VDS vs. Japan Model Code reference table to
determine the applicable flat rate time.
VDS
Model
VDS
Model
VN82D
VN82N
VN82R
VN82T
VN94T
VZN85
VN93D
VN93G
VZN90
VZN95
VZN100
VN02D
VZN105
VN29V
VZN120
VD10A
VD10B
VD10C
VCK10
VN01D
VN01G
VN13D
VN13G
VN39J
VN39W
VD20A
VD20C
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6.
Cylinder Head Gasket Kit
VZN110
VZN130
VCK20
3VZ–E Head Gasket SSC—V06
Page 5
FLAT RATE HOURS
VZN85
VZN100
VZN90
VZN105
VZN95
VZN110
VZN120
VZN130
VCK10
VCK20
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SSC V06
Operation Code
6.6
2.0
0.4
2.0
6.6
2.0
0.4
2.0
2 110011 R&R CYLINDER HEAD
Varied Work Code N
Comb Code A=Opposite cylinder head
Comb Code Z=Opposite head gasket
Comb Code L=A/C
Comb Code Z=Extra diagnostic time required
for SSC procedures
10.4
4.0
2.0
0.4
5.8
10.4
4.0
2.0
0.4
5.8
3 111011 R&R CYLINDER BLOCK
Varied Work Code N
Comb Code K=A/C
Comb Code Z=Replace one head
Comb Code Z=Replace both heads
16.3
0.4
2.0
4.0
18.2
0.4
2.0
4.0
4 120101 R&R SHORT BLOCK
Varied Work Code N
Comb Code K=A/C
Comb Code C=Replace one head
Comb Code CC=Replace both heads
14.5
0.4
2.0
4.0
16.4
0.4
2.0
4.0
5 EN7001 RESURFACE BLOCK
22.0
22.0
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1 110051 R&R HEAD GASKET
Varied Work Code N
Comb Code A=Opposite side
Comb Code L=A/C
Comb Code Z=Extra diagnostic time required
for SSC procedures
Claim Submission:
Use Claim Type = “RG.”
DSM authorization is required if the cylinder head or short block is replaced.
T1 = 64 (Leaks)
T2 = 13 (Deformed –bent, twisted, warped, shrunk, wrinkled)
OPN = 11115–XXXXX
Claim type “SC” cannot be used for this SSC.
Enter actual cost in sublet column using the following sublet types:
Rental
= “ZZ”
Machining = “MC”
Fluids
= “OF”
Towing
= “TW”
3VZ–E Head Gasket SSC—V06
Page 6
Enter CCR describing actual repair performed.
Rental Allowance:
7.
ED
Rentals for the SSC should be submitted on the repair claim using sublet
type “ZZ.” The rental guideline is a maximum 3 days at $30.00 per day. If
the rental is required for more than three days, or costs more than $30.00 per
day then DSM authorization is required on the claim. The rental should not
be submitted on a separate claim.
SSC Completion Label Installation
(a) After completing repair and before returning vehicle to the owner, the SSC completion
label that is enclosed in the owner’s notification must be affixed to the left front door hinge
post near the check strap.
(b) The label is to be filled out as follows:
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Write in SSC V06
Write in date of repair
Write in your Dealer Code
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(c) Additional SSC completion labels, in sheets of 50 (P/N 00410–01917), may be ordered
through the non–parts system on a 1450 order form or through the TDN system.
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TECHNICAL INSTRUCTIONS
FOR
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CYLINDER HEAD AND BLOCK INSPECTION
3VZ–E Cylinder Head/Block Inspection
Page 1
Please use the attached technical instructions to inspect the cylinder heads and blocks of
vehicles for warpage and erosion.
3VZ–E CYLINDER BLOCK AND HEAD SURFACE MACHINING
CYLINDER HEAD INSPECTION
ED
When replacing cylinder head gaskets on the 3VZ–E engine, careful inspection of the
cylinder head and block mating surfaces is necessary to ensure a complete and durable
repair. If cylinder head or block mating surfaces are warped or eroded, they may be
reconditioned using the following guidelines.
1.
CLEAN CYLINDER HEAD
(a). Using a gasket scraper, remove all the
gasket material from the cylinder block
contact surface.
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NOTE: Be careful not to scratch the cylinder
block contact surface.
(b). Using a wire brush, remove all the carbon
from the combustion chambers.
NOTE: Be careful not to scratch the cylinder
block contact surface.
(c). Using a sanding block with 180 grit paper,
thoroughly clean the cylinder block contact
surface.
3VZ–E Cylinder Head/Block Inspection
Page 2
2.
INSPECT CYLINDER HEAD FOR
FLATNESS.
ED
(a). Using a precision straight edge and feeler
gauge, measure the surfaces contacting
the cylinder block and the manifolds for
warpage.
CYLINDER HEAD MEASUREMENT
Less than More than 0.10
0.10 mm
mm (0.0039 in) but
(0.0039 in) less than 0.25 mm
(0.010 in)
Cylinder
*Cylinder head
head may may be machined
be reused to a maximum of
without
0.25 mm (0.010 in)
machining
More than
0.25 mm
(0.010 in)
Cylinder
head must
be
replaced
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NOTE: WHEN MACHINING CYLINDER
HEAD AND BLOCK THE COMBINED
AMOUNT OF MATERIAL REMOVED MUST
NOT EXCEED 0.25 mm (0.010 in).
3.
MEASURE CYLINDER BLOCK
CONTACT SURFACES FOR DEPTH OF
EROSION.
(a). Using a dial indicator, measure the depth
of erosion of the surfaces contacting the
cylinder head gasket.
4.
INSPECT VALVES AND VALVE SEATS.
(a). With the cylinder head inverted and the
spark plugs installed, fill the combustion
chambers with solvent to determine if any
of the valves or valve seats have been
damaged by the entry of coolant into the
cylinder.
3VZ–E Cylinder Head/Block Inspection
Page 3
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(b) Examine the intake and exhaust ports for
signs of the solvent leaking past the valve
seats, paying particular attention to
cylinders number one and number six. If
any solvent leakage is detected those
valves must be removed for further
inspection and repair as necessary.
3VZ–E Cylinder Head/Block Inspection
Page 4
CYLINDER BLOCK INSPECTION
1.
CLEAN TOP SURFACES OF PISTONS
AND CYLINDER BLOCK
ED
(a). Turn the crankshaft, and bring each
piston to top dead center (TDC). Using a
gasket scraper, remove all the carbon
from the piston top surface.
(b). Using a gasket scraper, remove all the
gasket material from the top surface of
the cylinder block.
(c). Using compressed air, blow carbon and
oil from the cylinders and bolt holes.
NOTE: Protect your eyes when using
compressed air.
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(d). Using a sanding block with 180 grit paper,
thoroughly clean the top surface of the
cylinder block.
2.
MEASURE TOP SURFACE OF
CYLINDER BLOCK FOR FLATNESS
(a). Using a precision straight edge and feeler
gauge, measure the surfaces contacting
the cylinder head gasket for warpage.
BLOCK MEASUREMENT
Less than
0.05 mm
(0.002 in)
Block may
be reused
without
machining
More than 0.05 mm
(0.002 in) but less
than 0.25 mm
(0.010 in)
*Block may be machined to a maximum of 0.25 mm
(0.010 in)
More than
0.25 mm
(0.010 in)
Replace
short
block
assembly
*NOTE: WHEN MACHINING CYLINDER
HEAD AND BLOCK THE COMBINED
AMOUNT OF MATERIAL REMOVED MUST
NOT EXCEED 0.25 mm (0.010 in).
3VZ–E Cylinder Head/Block Inspection
Page 5
3.
MEASURE TOP SURFACE OF
CYLINDER BLOCK FOR EROSION.
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CYLINDER WALL INSPECTION
ED
(a). Using a dial indicator, measure the depth
of erosion of the surfaces contacting the
cylinder head gasket.
1.
INSPECT CYLINDERS FOR VERTICAL
SCRATCHES
(a). Visually check the cylinders for vertical
scratches. If deep scratches are present,
replace the short block assembly.
3VZ–E Cylinder Head/Block Inspection
Page 6
PROCEDURE FOR INSPECTION OF COMPONENTS WHEN ENGINE MUST BE
DISASSEMBLED FOR MACHINING
CRANKSHAFT INSPECTION
CHECK CONNECTING ROD THRUST
CLEARANCE
ED
1.
(a). Using a dial indicator, measure the thrust
clearance while moving the connecting
rod back and forth.
Standard thrust clearance:
0.150 – 0.330 mm (0.0059 – 0.0130 in)
Maximum thrust clearance:
0.38 mm ( 0.0150 in)
If the thrust clearance is greater than
maximum, replace the short block assembly.
REMOVE CONNECTING ROD CAPS
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2.
(a). Using a punch or numbering stamp, mark
the connecting rod and cap to ensure
correct reassembly.
(b). Remove the connecting rod cap nuts.
(c). Using a plastic–faced hammer, lightly tap
the connecting rod bolts and lift off the
connecting rod cap.
NOTE: Keep the lower bearing inserted
with the connecting rod cap.
3VZ–E Cylinder Head/Block Inspection
Page 7
3.
REMOVE PISTON AND CONNECTING
ROD ASSEMBLIES
ED
(a). Using a ridge reamer, remove all the
carbon from the top of cylinder bore.
(b). Cover the connecting rod bolts with a
short piece of hose to protect the
crankshaft from damage.
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(c). 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 correct order.
4.
CHECK CRANKSHAFT THRUST
CLEARANCE
(a). Using a dial indicator, measure the thrust
clearance while prying the crankshaft
back and forth with a screwdriver.
Standard thrust clearance:
0.020 – 0.220 mm (0.0008 – 0.0087 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:
2.440 – 2.490 mm (0.0961 – 0.0980 in)
3VZ–E Cylinder Head/Block Inspection
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5. REMOVE MAIN BEARING CAP
(a). Uniformly loosen and remove the main
bearing cap bolts in several passes, in
the sequence shown.
(b). Using a screwdriver, pry up the main
bearing cap, and remove the main
bearing cap, lower main bearings and
lower thrust washers (No.2 journal
position of main bearing cap only).
NOTE: Keep the lower main bearings and
lower thrust washers together with the
main bearing cap.
(c). Lift out the crankshaft.
NOTE: Keep the upper main bearings and
upper thrust washers together with the
cylinder block.
6. INSPECT CRANKSHAFT FOR RUNOUT
(a). Place the crankshaft on V – blocks.
(b). Using a dial indicator, measure the circle
runout at the No.2 and No.3 journals.
Maximum circle runout:
0.06mm (0.0024 in)
If the circle runout is greater than maximum,
replace the short block assembly.
7. INSPECT MAIN JOURNALS AND
CRANK PINS
(a). Using a micrometer, measure the
diameter of each main journal and crank
pin.
Main journal diameter:
STD: 64.000 mm (2.5191 – 2.5197 in)
Crank pin diameter:
STD: 55.000 mm (2.1648 – 2.1654 in)
If the diameter is not as specified, replace the
short block assembly.
(b). Check each main journal and crank pin
for taper and out–of–round as shown.
Maximum taper and out–of–round:
0.02 mm (0.0008 in)
If the taper or out–of–round is greater than
maximum, replace the short block assembly.
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When reassembling the engine selectively fit the crankshaft bearings according to the
numbers marked on the crankshaft, block and connecting rods.
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NOTE: If using a standard bearing, replace 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 five sizes of standard bearings, marked “1,” “2,”
“3,” “4,” and “5,” accordingly.
Number marked
Cylinder block
1
2
3
Crankshaft
0 1 2 0 1 2 0 1 2
Use bearing
1 2 3 2 3 4 3 4 5
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EXAMPLE: Cylinder block “2” + Crankshaft “1”
= Total number 3 (Use bearing “3”)
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Page 10
MACHINING INSTRUCTIONS
If the crankshaft connecting rods and pistons are serviceable and the cylinder block is not
warped or eroded beyond specification, the block cylinder head surface may be machined.
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In order to perform this machining operation correctly, equipment that will produce a
smooth, flat, and scratch free surface must be utilized. In addition, this machine must be
capable of accurately measuring the amount of material that is being removed. Following
this machining operation the amount of material that has been removed must be indicated
on the cylinder head and/or block by stamping the end surface as indicated.
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If you are uncertain as to whether or not a cylinder head or block has previously been
machined, confirm the measurement of the head and/or block using the dimensions
provided below.
Always thoroughly clean a head or block that has been machined to ensure that all residue
from the machining operation is completely removed.