Engine Unit

1ZZ-FE ENGINE MECHANICAL: ENGINE UNIT:

INSPECTION

1. INSPECT CHAIN TENSIONER ASSEMBLY NO.1





(a) Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.
(b) Release the ratchet pawl, then check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
2. INSPECT CHAIN SUB-ASSEMBLY





(a) Using a spring tension gauge and vernier calipers, pull the timing chain with 140 N (14.3 kgf, 31.5 lb), then measure its length.
Maximum chain elongation:
115.3 mm (4.539 in.)
If the chain elongation is greater than maximum, replace the chain.

HINT: Take the same measurements by pulling at 3 or more places selected at random.

3. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET





(a) Wrap the chain around the camshaft timing gear.
(b) Using vernier calipers, measure the diameter of the timing gear with the chain wrapped.
Minimum gear diameter (w/ chain):
96.8 mm (3.811 in.)

NOTE: The vernier calipers must be in contact with the chain rollers when measuring.

If the diameter is less than minimum, replace the chain and camshaft timing gear.
4. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET





(a) Wrap the chain around the crankshaft timing gear.
(b) Using vernier calipers, measure the crankshaft timing gear diameter with the chain.
Minimum gear diameter (w/ chain):
51.0 mm (2.008 in.)

NOTE: The vernier calipers must be in contact with the chain rollers when measuring.

If the diameter is less than minimum, replace the chain and crankshaft timing gear.
5. INSPECT CHAIN TENSIONER SLIPPER





(a) Using verniers calipers, measure the chain tensioner slipper wear.
Maximum wear:
1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the chain tensioner slipper.
6. INSPECT CHAIN VIBRATION DAMPER NO.1





(a) Using vernier calipers, measure the vibration damper wears.
Maximum wear:
1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the chain vibration damper.
7. INSPECT CYLINDER HEAD SET BOLT





(a) Using vernier calipers, measure the length of the cylinder head bolts from the seat to the end.
Standard bolt length:
146.8 to 148.2 mm (5.780 to 5.835 in.)
Maximum bolt length:
148.5 mm (5.846 in.)
If the bolt length is greater than maximum, replace the cylinder head set bolt.
8. INSPECT CAMSHAFT





(a) Check the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout:
0.03 mm (0.0012 in.)
If the circle runout is greater than maximum, replace the camshaft.





(b) Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake
44.333 to 44.433 mm (1.7454 to 1.7493 in.)
Exhaust
43.761 to 43.861 mm (1.7229 to 1.7268 in.)
Minimum cam lobe height:
Intake
44.18 mm (1.7394 in.)
Exhaust
43.61 mm (1.7169 in.)
If the cam lobe height is less than minimum, replace the camshaft.





(c) Inspect the camshaft journals.
(1) Using a micrometer, measure the journal diameter.
No. 1 journal diameter:
34.449 to 34.465 mm (1.3563 to 1.3569 in.)
Other journal diameters:
22.949 to 22.965 mm (0.9035 to 0.9041 in.)
If the journal diameter is not as specified, check the oil clearance.
9. CHECK CYLINDER BLOCK FOR FLATNESS





(a) Using a precision straight edge and feeler gauge, measure the warpage on the surface that is in contact with the cylinder head gasket.
Maximum warpage:
0.05 mm (0.0020 in.)
If the warpage is greater than maximum, replace the cylinder block.
10. INSPECT CYLINDER BORE





(a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
Standard diameter:
79.000 to 79.013 mm (3.1102 to 3.1107 in.)
Maximum diameter::
79.133 mm (3.1155 in.)
If the average diameter of 4 positions is greater than maximum, replace the cylinder block.
11. INSPECT W/PIN PISTON SUB-ASSEMBLY





(a) Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at a piston of 28.0 mm (1.102 in.) from the top the piston head.
Piston diameter:
78.917 to 78.927 mm (3.1070 to 3.1074 in.)
If the diameter is not as specified, replace the piston assembly.
12. CHECK PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance:
0.073 to 0.096 mm (0.0029 to 0.0038 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)

- If the oil clearance is greater than maximum, replace all pistons.
- If necessary, replace the cylinder block.

13. CHECK PISTON PIN OIL CLEARANCE





(a) Using a caliper gauge, measure the piston pin bore diameter.
Piston pin bore diameter:
20.006 to 20.015 mm (0.7876 to 0.7880 in.)





If the bore diameter is not as specified, replace the piston assembly.





(b) Using a micrometer, measure the piston pin outer diameter.
Piston pin outer diameter:
20.004 to 20.013 mm (0.7876 to 0.7879 in.)





If the outer diameter is not as specified, replace the piston assembly.





(c) Using a caliper gauge, measure the connecting rod small end bore diameter.
Connecting rod small end bore diameter:
20.012 to 20.021 mm (0.7879 to 0.7882 in.)





If the diameter is not as specified, replace the connecting rod assembly.





(d) Subtract the piston pin outer diameter measurement from the piston pin bore diameter measurement.
Standard oil clearance:
0.002 to 0.011 mm (0.0001 to 0.0004 in.)
Maximum oil clearance:
0.011 mm (0.0004 in.)

- If the oil clearance is greater than maximum, replace the connecting rod assembly.
- If necessary, replace the piston assembly.

(e) Subtract the piston pin outer diameter measurement from the connecting rod small end bore diameter measurement.
Standard oil clearance:
-0.001 to 0.017 mm (-0.00004 to 0.0007 in.)
Maximum oil clearance:
0.017 mm (0.0007 in.)

- If the oil clearance is greater than maximum, replace the connecting rod assembly.
- If necessary, replace both the connecting rod assembly and piston assembly.

14. CHECK RING GROOVE CLEARANCE





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





If the groove clearance is not as specified, replace the piston assembly.
15. CHECK PISTON RING END GAP





(a) Using a 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.





(b) Using a feeler gauge, measure the end gap.
Standard end gap:





Maximum 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.

16. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) Using a connecting rod aligner and feeler gauge, check the connecting rod alignment.





(1) Check for misalignment.
Maximum misalignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If the misalignment is greater than maximum, replace the connecting rod assembly.





(2) Check for twist.
Maximum twist:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If the twist is greater than maximum, replace the connecting rod assembly.
17. INSPECT CONNECTING ROD BOLT





(a) Using vernier calipers, measure the tension portion diameter of the bolts.
Standard diameter:
6.6 to 6.7 mm (0.260 to 0.264 in.)
Minimum diameter:
6.4 mm (0.252 in.)
If the diameter is less than minimum, replace the connecting rod bolt.
18. INSPECT CRANKSHAFT





(a) Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration.
Maximum circle runout:
0.03 mm (0.0012 in.)
If the circle runout is greater than maximum, replace the crankshaft.





(b) Using a micrometer, measure the diameter of each main journal at the points shown in the illustration.
Diameter:
47.988 to 48.000 mm (1.8893 to 1.8898 in.)
If the diameter is not as specified, check the crankshaft oil clearance.
(c) Check each main journal for taper and distortion as shown.
Maximum taper and distortion:
0.02 mm (0.0008 in.)
If the taper and distortion are greater than maximum, replace the crankshaft.





(d) Using a micrometer, measure the diameter of each crank pin at the points shown in the illustration.
Diameter:
43.992 to 44.000 mm (1.7320 to 1.7323 in.)
If the diameter is not as specified, check the connecting rod oil clearance.
(e) Check each crank pin for taper and distortion.
Maximum taper and distortion:
0.02 mm (0.0008 in.)
If the taper and distortion are greater than maximum, replace the crankshaft.
19. INSPECT CRANKSHAFT BEARING CAP SET BOLT





(a) Using vernier calipers, measure the tension portion diameter of the bolts.
Standard diameter:
7.3 to 7.5 mm (0.287 to 0.295 in.)
Minimum diameter:
7.3 mm (0.287 in.)
If the diameter is less than minimum, replace the crankshaft bearing cap set bolt.
20. CHECK CRANKSHAFT OIL CLEARANCE

NOTE: Do not turn the crankshaft.





(a) Clean each main journal and bearing.
(b) Place the crankshaft on the cylinder block.
(c) Lay a strip of the Plastigage across each journal.





(d) Using SST, tighten the bolts to the specified torque in the several passes in the sequence shown.
Torque: 44 Nm (449 kgf-cm, 33 ft-lbf)





(e) Mark the front of the bearing cap bolts with paint.
(f) Retighten the bearing cap bolts by 90° as shown in the illustration.
(g) Check that the painted mark of each bolt is now at a 90° angle to the front.





(h) Tighten the 10 other bolts for the bearing cap.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
(i) Remove the 10 bolts.





(j) Uniformly loosen the 10 bearing cap bolts in several passes in the sequence shown in the illustration.





(k) Measure the Plastigage at its widest point.
Standard oil clearance:
0.015 to 0.032 mm (0.0006 to 0.0013 in.)
Maximum oil clearance:
0.05 mm (0.0020 in.)

NOTE: Completely remove the Plastigage.

- If the oil clearance is greater than maximum, replace the crankshaft bearing.
- If necessary, replace the crankshaft.

HINT: If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft, then select a new bearing with the calculated number. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.





EXAMPLE:
Cylinder block "3" (A) + Crankshaft "4" (B) = Total number 7 (Use bearing "3")