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The following technical bulletins were published by AERA.


                                           Cylinder Boring Caution For
                          1986-99 Toyota 1.5, 2.0 & 2.2L 5E, 3S & 5S Engines

The AERA Technical Committee offers the following information regarding a cylinder boring caution for 1986-99 Toyota 1.5, 2.0 & 2.2L 5E, 3S & 5S engines. AERA originally published information regarding only the 1.5L engine. This publication includes additional engines with a similar concern. This caution has been reported on engines that have been bored to a .040 (1.000 mm) oversize diameter. 

Apparently, depending on the amount of overbore the cylinder wall thickness may become insufficient to support compression. Reports of compression in the cooling system have resulted when the bore diameter has been increased by as little as .040 (1.000 mm) oversize.  

These blocks have three angular coolant passages between the cylinders as shown below in Figure 1. The passages are drilled at approximately a 45° angle from the engine right side to the engine left side. These passages allow coolant flow between the cylinders and connect the right to left side water jackets.

The shadow of the drilled passage can be seen in Figure 2 as a dark shadow on a failed block that had been bored and honed .040 and placed back in service. Combustion pressure within the cylinder after start-up created the through hole into the water jacket, resulting in combustion in the cooling system. Engine overheating will result when this condition exists. To repair this condition, AERA members report installing cylinder sleeves and then boring back to a standard bore diameter for all cylinders.

                                                                               The AERA Technical Committe


                               Piston & Rod Assembly & Rod Bolt Reuse for 
                          1989-99 Toyota 1.6 & 1.8L 4A-FE & 7A-FE Engines

The AERA Technical Committee offers the following information on piston and rod assembly and rod bolt reuse for 1989-99 Toyota 1.6 & 1.8L 4A-FE & 7A-FE engines. This information should be used to correctly assemble the pistons to connecting rods and determine whether a connecting rod bolt should be considered for reuse.

Rod bolts considered for reuse should be free of nicks and burrs and allow easily threading the bolt or nut with one's fingers. To further consider the rod bolts for a 1.6L engine, measure the bolt diameter with a caliper at .590 (14.986 mm) from the bottom of the bolt. If the diameter measured at that location is .3386 (8.6000 mm) or greater the bolt may be reused.

To further consider the rod bolts for a 1.8L engine, measure the bolt diameter with a caliper at .787 (20.000 mm) down from the bottom of the connecting rod bolt head. If the diameter measured at that location is .270 (7.000 mm) or greater the bolt may be reused
To assemble the connecting rods for either engine to the pistons, align the protrusion or front mark on the rod with the front mark located on the piston as shown in the illustrations below.

                                                                            The AERA Technical Committee


                                  Connecting Rod Nut Tightening Caution On
                                          Toyota 2.5 & 3.0L Engines

AERA machine shops should be particularly cautious when tightening the connecting rod nuts on Toyota 2.5 & 3.0L V-6 engines used in the 4 Runner and Pickup.  

The connecting rod nuts for these engines use a combination torque, then turn method to achieve the proper clamping load.  First the nut is torqued to 18 lbs.ft., then turned an additional 90°.  It is possible for the rod bolt to slightly turn inside the connecting rod during this process, causing the final torque to be below specifications.  The nut must be turned 90° relative to the bolt, not the connecting rod.  

During assembly, instead of marking the nut and the connecting rod with a paint stick, mark the nut and the bolt to ensure that the proper final torque is achieved.

                                                                      The AERA Technical Committee


                                       Coolant In The Oil On
                                  Toyota 20R & 22R Engines

AERA members have reported instances of engine coolant mixing with the engine lubricating oil supply.

In some of these cases, pressure testing the cylinder block and head has not identified the source of the leak.  However, close inspection of the aluminum front cover revealed an area where the timing chain wore through into a water passage.  

In this engine the water pump is mounted to the front cover.  When the timing chain stretches and the automatic tensioner is no longer able to take up the slack, the loose chain can slap against the front cover.  Continuous contact will eventually wear a hole into the front cover, introducing engine coolant into the

                                                                      The AERA Technical Committee


                     Flywheel Specifications

The following flywheel specifications may be used as reference
when surfacing flywheels.

                   Type of 
Manufacturer       flywh. Specs.          Comments

BMW                Step   .013 - .015
Datsun             Step   .003 - .005   No groove
                   Flat                   With groove
Datsun 240Z        Step   .010           With groove
Fiat Spider 1600   Step   .018
Ford Falcon        Cup    .018           6 Cylinder engines
Ford Courier       Cup    .285
                   Cup    .310
Ford Ranger        Cup    .003           V6 Cylinder engines
GM                 Cup    .125
GM - Buick         Cup    .125           V6 Cylinder engines
GM - Spirit        Cup    .195
Honda              Cup    .030           Small cup
                   Cup    .100 - .104   
                   Cup    .785           Long alignment pins
                   Cup    .900            Short alignment pins
Honda Accord       Cup    .615           
Mazda              Cup    .062           Rotary engines
Subaru             Cup    .785
Toyota             Step   .018 - .022   Large alignment pins
                   Cup    .055           Small cup
                   Cup    .965 - .970    Tercel, large cup
                   Step   .040           Tercel, step
                   Step   .020           Land Cruiser
VW                 Cup    .945           Air cooled, 6 Volt
                   Cup    .830           Scirocco
                   Cup    .835           Rabbit/Golf
                   Cup    .982           Air cooled bus engine
                   Cup    .830           Air cooled engine
                   Cup    .885           Air cooled engine

Specifications listed for Step type flywheels refer to the
height of the wear surface above the pressure plate mounting
surface.  Specifications for Cup type flywheels refer to the
height of the pressure plate mounting surface above the wear

                                     The AERA Technical Committee

February 1988 - SB 153



                                           Valve Lash Adjustment For
                                       1998-2003 Toyota 1.8L Engines

The AERA Technical Committee offers the following information regarding valve lash adjustment for 1998-2003 Toyota 1.8L engines. Beginning in the year 2000 Toyota offered two engines with the 1.8L designation. They can be identified first by a 1ZZ-FE (1762 CC) engine, and then a 2ZZ-GE (1794 CC) engine. 

The valve lash specification for exhaust locations is different for the two engines. Refer to the chart below while adjusting valves for these engines.  

Years                        Engine                       Location                     Specification

1998-2003           1ZZ-FE                           Exhaust              .010-.014 (.25-.35 MM)
                            1ZZ-FE                            Intake                 .006-.010 (.15-.25 MM)

2000-2003           2ZZ-GE                          Exhaust                .014-.018 (.35-.45 MM)
                            2ZZ-GE                           Intake                  .006-.010 (.15-.25 MM)

These engines use different methods of adjusting the clearance; the 1ZZ-FE uses one of thirty-five different thickness lifters, while the 2ZZ-GE uses one of forty-one different lash caps. The 1ZZ-FE also requires camshaft removal to facilitate lifter replacement (lash adjustment), whereas the 2ZZ-GE lash cap replacement to perform valve lash adjustment. 

                                                                           The AERA Technical Committee


                                             Valve Seal Identification For
                                           2000-2002 Toyota 1.8L Engines

The AERA Technical Committee offers the following information on valve seal identification for 2000-2002 Toyota 1.8L engines.  Starting with the 2000-year model Toyota offered two 1.8L engines with similar displacement, a 1ZZ-FE and a 2ZZ-GE designation.  

Determining which engine you're working on may be confusing, as many components are similar.  Valve stem seals fall into the confusing category, as they physically appear the same at first glance. Original equipment and some aftermarket seals are color coded to ease in seal identification. Refer to the chart and Figure 1 below to help identify the seals once they?re out of their original packaging.

Engine Model         Location         Coloring         Part Number      Stem Diameter

     1ZZ-FE               Exhaust             Gray             9008031046         .2152-.2157  
     1ZZ-FE               Intake          Light Brown        9091302101         .2154-.2159  

     2ZZ-GE             Exhaust             Green            9091302115          .2144-.2154 
     2ZZ-GE             Intake                Black             9091302114          .2150-.2156  

Valve guides are also slightly different between the two engines, which offers additional means of engine identification. The installed guide height and the guide outside diameter are different as the 2ZZ-GE engine protrudes higher than the 1ZZ-FE.  The 2ZZ-GE guides should be .602-.618 above the spring seat while the 1ZZ-FE guides should be .342-.358 above the spring seat.

                                                                        The AERA Technical Committee


                                        Revised Timing Belt &Tensioner Spring For
                                            1992-96 Toyota 2.2L 5S-FE Engines

The AERA Technical Committee offers the following information on a revised timing belt tensioner spring for 1992-96 Toyota 2.2L 5S-FE engines. This information should be considered anytime the timing belt is removed from the engine.

The timing belt and tensioner spring for 5S-FE engines has been revised beginning with the 1997-year model. The timing belt and spring are designed for use, as a set and one should not be replaced without replacing the other. All 1992-96 engines should be updated with the revised spring and belt as a set for improved durability. Intermixing prior and revised components should not be attempted as improper tension and alignment may occur. 

Prior Part  Number      Current Part Number            Description
     90507-18030            90507-17003                       Tension Spring
     13568-09040            3568-09041                         Timing Belt

Its 4mm shorter length and additional 3 coils can identify the revised spring.

                                                                          The AERA Technical Committee

Flywheel Assembly Revisions

                                       Flywheel Assembly Revisions On
                                1988-92 Toyota 4.0L Landcruiser Engines

Toyota has changed the flywheel assembly and crankshaft on 4.0L engines installed in the Landcruiser starting with the model produced in October of 1989.  The revised engines carry an engine number of 3F-250226 or later.
The obvious difference between the former and the revised design is the flywheel bolts.  Formerly these were 10x1.25mm bolts that were 32mm long.  The revised bolts are 11x1.25mm and only 26mm long.  

All of the components, including the crankshaft, are only interchangeable as a set.  Be sure to verify the type of flywheel assembly and crankshaft that is being used when remanufacturing and installing Toyota 4.0L Landcruiser engines.

                                  1988 through                      Oct. of 1989 
Part                           Sep. of 1989                       through 1992
Description              Part Number                       Part Number

Flywheel Bolt           90105-10115                       90105-11030
Crankshaft                13401-61021                       13401-61023
Flywheel                   32101-60010                       32101-60011
Spacer, Front           32116-60010                       32116-60011
Spacer, Rear           32117-60010                       32117-60011

                                                                                The AERA Technical Committee

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