Engine Unit

2AZ-FE ENGINE MECHANICAL: ENGINE UNIT:

INSPECTION

1. INSPECT BALANCESHAFT THRUST CLEARANCE
(a) Install the balanceshafts (Reassembly).

(b) Using a dial indicator, measure the thrust clearance while moving the balanceshaft back and forth.
Standard thrust clearance:
0.05 to 0.09 mm (0.0020 to 0.0035 in.)
Maximum thrust clearance:
0.09 mm (0.0035 in.)
If the thrust clearance is greater than the maximum, replace the balanceshaft housing and bearings. If necessary, replace the balanceshaft.
2. INSPECT BALANCESHAFT OIL CLEARANCE
(a) Clean each bearing and journal.
(b) Check each bearing and journal for pitting and scratches. If a bearing or journal is damaged, replace the bearings. If necessary, replace the balanceshaft.
(c) Place the No. 1 and No. 2 balanceshafts onto the crankcase.

(d) Lay a strip of Plastigage across each journal.
(e) Install the balanceshaft housing (Reassembly).

NOTE: Do not turn the balanceshafts.

(f) Remove the balanceshaft housing (Disassembly).

(g) Measure the Plastigage at its widest point.
Standard oil clearance:
0.004 to 0.049 mm (0.0002 to 0.0019 in.)
Maximum oil clearance:
0.049 mm (0.0019 in.)

NOTE: Remove the Plastigage completely after the measurement.

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

(h) If replacing a bearing, select a new one with the same number.

HINT: If replacing a bearing, replace it with one that has the same number as the stiffening crankcase. there are 3 sizes of standard bearings: 1, 2 and 3.

Standard balanceshaft housing journal bore diameter:

Standard bearing center wall thickness:

Standard balanceshaft journal diameter:

(i) Inspect the balanceshaft housing bolts.

(1) Using vernier calipers, measure the length of the bolts from the seat to the end.
Standard bolt length:
58.3 to 59.7 mm (2.295 to 2.350 in.)
Maximum bolt length:
60.3 mm (2.374 in.)
If the bolt length is greater than the maximum, replace the balanceshaft housing bolt.
3. INSPECT CHAIN SUB-ASSEMBLY

(a) Pull the chain with a force of 140 N (14.3 kgf, 31.5 lbf) as shown in the illustration.
(b) Using vernier calipers, measure the length of 15 links.
Maximum chain elongation:
114.5 mm (4.508 in.)

NOTE: Perform the measurement at 3 random places. Use the average of the measurements.

If the average elongation is greater than the maximum, replace the chain.
4. INSPECT NO. 2 CHAIN SUB-ASSEMBLY

(a) Pull the chain with a force of 140 N (14.3 kgf, 31.5 lbf) as shown in the illustration.
(b) Using vernier calipers, measure the length of 15 links.
Maximum chain elongation:
102.2 mm (4.024 in.)

NOTE: Perform the measurement at 3 random places. Use the average of the measurements.

If the average elongation is greater than the maximum, replace the No. 2 chain.
5. INSPECT OIL PUMP DRIVE GEAR

(a) Place the chain around the drive gear.
(b) Using vernier calipers, measure the diameter of the drive gear and chain.
Minimum gear diameter (with chain):
48.2 mm (1.898 in.)

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

If the diameter is less than the minimum, replace the chain and gear.
6. INSPECT OIL PUMP DRIVE SHAFT GEAR

(a) Place the chain around the driven shaft gear.
(b) Using vernier calipers, measure the diameter of the driven shaft gear and chain.
Minimum gear diameter (with chain):
48.2 mm (1.898 in.)

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

If the diameter is less than the minimum, replace the chain and drive shaft gear.
7. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

(a) Place the chain around the timing gear.
(b) Using vernier calipers, measure the diameter of the timing gear and chain.
Minimum gear diameter (with chain):
97.3 mm (3.831 in.)

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

If the diameter is less than the minimum, replace the chain and timing gear.
8. INSPECT CAMSHAFT TIMING SPROCKET

(a) Place the chain around the timing sprocket.
(b) Using a vernier calipers, measure the diameter of the timing sprocket and chain.
Minimum sprocket diameter (with chain):
97.3 mm (3.831 in.)

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

If the diameter is less than the minimum, replace the chain and timing sprocket.
9. INSPECT CRANKSHAFT TIMING GEAR

(a) Place the chain around the timing gear.
(b) Using a vernier calipers, measure the diameter of the timing gear and chain.
Minimum gear diameter (with chain):
51.6 mm (2.031 in.)

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

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

(a) Measure the tensioner slipper wear.
Maximum wear:
1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the tensioner slipper.
11. INSPECT NO. 1 CHAIN VIBRATION DAMPER

(a) Measure the vibration damper wear.
Maximum wear:
1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the vibration damper.
12. INSPECT CHAIN TENSIONER PLATE

(a) Using vernier calipers, measure the vibration damper wear.
Maximum wear:
0.5 mm (0.020 in.)
If the wear is greater than the maximum, replace the chain tensioner plate.
13. INSPECT NO.1 CHAIN TENSIONER ASSEMBLY

(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.
14. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Install the connecting rod cap (Reassembly).

(b) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance:
0.160 to 0.362 mm (0.0063 to 0.0143 in.)
Maximum thrust clearance:
0.362 mm (0.0143 in.)
If the thrust clearance is greater than the maximum, replace the connecting rod assemblies as necessary. If necessary, replace the crankshaft.
15. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Clean the crank pin and bearing.
(b) Check the crank pin and bearing for pitting and scratches.

(d) Check that the front mark of the connecting rod cap is facing forward.
(e) Install the connecting rod cap (Reassembly).

NOTE: Do not turn the crankshaft.

(f) Remove the 2 bolts and connecting rod cap (Disassembly).

(g) Measure the Plastigage at its widest point.
Standard oil clearance:
0.032 to 0.063 mm (0.0013 to 0.0025 in.)
Maximum oil clearance:
0.063 mm (0.0025 in.)
If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.

NOTE: Completely remove the Plastigage after the measurement.

HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, or 3 mark on its surface.

Standard connecting rod large end bore diameter:

Standard connecting rod bearing thickness:

Standard crankshaft pin diameter:

16. INSPECT CYLINDER BLOCK FOR WARPAGE

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

(a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in both thrust and axial directions.
Standard diameter:
88.500 to 88.513 mm (3.4843 to 3.4847 in.)
Maximum diameter:
88.633 mm (3.4894 in.)
If the diameters is greater than the maximum, replace the cylinder block.
18. INSPECT PISTON DIAMETER

(a) Using a gasket scraper, remove the carbon from the piston top.

(b) Using a groove cleaning tool or broken ring, clean the piston ring grooves.

(d) Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at a point 30.3 mm (1.193 in.) from the piston head.
Piston diameter:
88.439 to 88.449 mm (3.4818 to 3.4822 in.)
19. INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance:
0.051 to 0.074 mm (0.0020 to 0.0029 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)
If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.
20. INSPECT RING GROOVE CLEARANCE

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

Ring groove clearance:
0.030 to 0.070 mm (0.0012 to 0.0028 in.)
If the clearance is not as specified, replace the piston.
21. INSPECT 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 the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, replace the cylinder block.
22. INSPECT PISTON PIN OIL CLEARANCE

(a) Using a caliper gauge, measure the piston pin bore diameter.
Standard piston pin bore diameter:
22.001 to 22.010 mm (0.8662 to 0.8665 in.)
Standard piston pin bore diameter (Reference):

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

(b) Using a micrometer, measure the piston pin diameter.
Standard piston pin diameter:
21.997 to 22.009 mm (0.8660 to 0.8665 in.)
Piston pin diameter (Reference):

If the diameter is not as specified, replace the piston pin.

(c) Using a caliper gauge, measure the connecting rod small end bore diameter.
Standard connecting rod small end bore diameter:
22.005 to 22.014 mm (0.8663 to 0.8667 in.)
Standard connecting rod small end bore diameter (Reference):

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

(d) Subtract the piston pin diameter measurement from the piton pin hole diameter measurement.
Standard oil clearance:
0.001 to 0.007 mm (0.00004 to 0.0003 in.)
Maximum oil clearance:
0.010 mm (0.0004 in.)
If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set.
(e) Subtract the piston pin diameter measurement from the connecting rod small end bore diameter measurement.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance:
0.011 mm (0.0004 in.)
If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the connecting rod and piston pin as a set.
23. INSPECT CONNECTING ROD BOLT

(a) Using vernier calipers, measure the tension portion diameter of the bolt.
Standard diameter:
7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter:
7.0 mm (0.276 in.)
If the diameter is less than the minimum, replace the connecting rod bolt.
24. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) Using a rod aligner and feeler gauge, check the connecting rod alignment.

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

(2) Check for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum, replace the connecting rod assembly.
25. 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 taper and distortion are greater than the maximum, replace the crankshaft.

(b) Using a micrometer, measure the diameter of each main journal.
Standard diameter:
54.988 to 55.000 mm (2.1649 to 2.1654 in.)
If the diameter is not as specified, check the crankshaft oil clearance.
(c) Check each main journal for taper and distortion as shown in the illustration.
Maximum taper and distortion:
0.003 mm (0.0001 in.)
If the taper and distortion are greater than the maximum, replace the crankshaft.
Standard diameter (Reference):

(d) Using a micrometer, measure the diameter of each crank pin.
Diameter:
47.990 to 48.000 mm (1.8894 to 1.8898 in.)
If the diameter is not as specified, check the connecting rod oil clearance.
(e) Inspect each crank pin for taper and distortion as shown in the illustration.
Maximum taper and distortion:
0.003 mm (0.0001 in.)
If the taper and distortion are greater than the maximum, replace the crankshaft.
26. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Install the main bearing cap (Reassembly).

(b) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.04 to 0.24 mm (0.0016 to 0.0095 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set.

HINT: The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.).

27. INSPECT CRANKSHAFT OIL CLEARANCE
(a) Check the crank journal and bearing for pitting and scratches.
(b) Install the crankshaft bearing (Reassembly).
(c) Place the crankshaft on the cylinder block.

(d) Lay a strip of Plastigage across each journal.
(e) Examine the front marks and numbers and install the bearing caps on the cylinder block.

HINT: A number is marked on each main bearing cap to indicate the installation position.

(f) Install the main bearing cap (Reassembly).

NOTE: Do not turn the crankshaft.

(g) Remove the main bearing caps (Disassembly).

(h) Measure the Plastigage at its widest point.
Standard oil clearance:
0.017 to 0.040 mm (0.0007 to 0.0016 in.)
Maximum oil clearance:
0.060 mm (0.0024 in.)
If the oil clearance is greater than the maximum, replace the crankshaft bearing. If necessary, replace the crankshaft.

NOTE: Remove the Plastigage completely after the measurement.

- 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 according to the chart below. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.
- EXAMPLE: Cylinder block "3" + Crankshaft "5" = Total number 8 (Use bearing "3")

Standard cylinder block journal bore diameter:

Standard crankshaft journal diameter:

Standard bearing center wall thickness:

28. 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:
7.2 mm (0.284 in.)
If the diameter is less than the minimum, replace the bolt.
29. INSPECT CAMSHAFT

(a) Inspect 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 the maximum, replace the camshaft.

(b) Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
47.306 to 47.406 mm (1.8624 to 1.8664 in.)
Minimum cam lobe height:
47.196 mm (1.8581 in.)
If the cam lobe height is less than the minimum, replace the camshaft.

If the journal diameter is not as specified, check the oil clearance.
30. INSPECT NO. 2 CAMSHAFT

(b) Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
46.063 to 46.163 mm (1.8135 to 1.8174 in.)
Minimum cam lobe height:
45.953 mm (1.8092 in.)
If the cam lobe height is less than the minimum, replace the No. 2 camshaft.

(c) Inspect the camshaft journals.
(1) Using a micrometer, measure the journal diameter.
No. 1 journal diameter:
35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Other journal diameter:
22.959 to 22.975 mm (0.9039 to 0.9045 in.)
If the journal diameter is not as specified, check the oil clearance.
31. INSPECT CYLINDER HEAD SET BOLT

(a) Using a vernier caliper, measure the length of the head bolts from the seat to the end.
Standard bolt length:
141.3 to 142.7 mm (5.563 to 5.618 in.)
Maximum bolt length:
144.2 mm (5.677 in.)
If the bolt length is greater than the maximum, replace the cylinder head set bolt.