Engine Unit
2AZ-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION
INSPECTION
1. INSPECT CYLINDER BLOCK FOR WARPAGE
(a) Using a precision straightedge and feeler gauge, measure the warpage of 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 the maximum, replace the cylinder block.
2. 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:
88.500 to 88.513 mm (3.4843 to 3.4848 in.)
Maximum diameter:
88.633 mm (3.4895 in.)
If the average diameter of the 4 positions is greater than the maximum, replace the cylinder block.
3. INSPECT PISTON
(a) Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at the piston 30.3 mm (1.193 in.) from the piston head.
Standard piston diameter:
88.439 to 88.449 mm (3.4819 to 3.4822 in.)
If the diameter is not as specified, replace the piston.
4. 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.
5. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between the new piston ring and wall of the ring groove.
Standard ring groove clearance:
If the groove clearance is not as specified, replace the piston.
6. 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.
7. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the piston pin bore diameter.
Standard piston pin bore diameter:
22.001 to 22.010mm (0.8662 to 0.8665 in.)
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 22.006 mm (0.8660 to 0.8664 in.)
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.)
If the diameter is not as specified, replace the connecting rod.
(d) Subtract the piston pin diameter measurement from the piston pin bore diameter measurement.
Standard oil clearance:
0.001 to 0.007 mm (0.00004 to 0.0003 in.)
Maximum oil clearance:
0.013 mm (0.0005 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:
0.017 mm (0.0007 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.
8. 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 the maximum, replace the connecting rod.
(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.
9. 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.)
Maximum diameter:
7.0 mm (0.276 in.)
If the diameter is less than the minimum, replace the connecting rod bolt.
10. INSPECT CRANKSHAFT
(a) Using a dial indicator and V-blocks, measure the circle runout 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.
(b) Using a micrometer, measure the diameter of each main journal.
Standard diameter:
54.998 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.
Standard 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.
11. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using vernier calipers, measure the tension portion diameter of the bolts.
Standard diameter:
7.5 to 7.6 mm (0.295 to 0.299 in.)
Minimum diameter:
7.5 mm (0.295 in.)
If the diameter is less than the minimum, replace the bolt.