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.
NOTICE:
Do not turn the balanceshafts.
(f) Remove the balanceshafts 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.)
NOTICE:
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.
Standard balanceshaft housing journal bore diameter:
Standard bearing center wall thickness:
Standard balanceshaft journal diameter:
(i) Inspect the balanceshaft housing bolts.
(1) Using vernier caliper, 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 caliper, measure the length of 15 links.
Maximum chain elongation:
114.5 mm (4.508 in.)
NOTICE:
Perform the measurement at 3 random places. Use the average of the measurements.
If the 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 caliper, measure the length of 15 links.
Maximum chain elongation:
102.2 mm (4.024 in.)
NOTICE:
Perform the measurement at 3 random places. Use the average of the measurements.
If the elongation is greater than the maximum, replace the No. 2 chain.
5. INSPECT OIL PUMP DRIVE GEAR
(a) Wrap the chain around the sprocket.
(b) Using vernier caliper, measure the sprocket diameter with the chain wrapped around.
Minimum gear diameter (with chain):
48.2 mm (1.898 in.)
NOTICE:
The vernier caliper must be in contact with the chain rollers when measuring.
If the diameter is less than the minimum, replace the chain and sprocket.
6. INSPECT OIL PUMP DRIVE SHAFT GEAR
(a) Wrap the chain around the sprocket.
(b) Using vernier caliper, measure the sprocket diameter with the chain wrapped around.
Minimum gear diameter (with chain):
48.2 mm (1.898 in.)
NOTICE:
The vernier caliper must be in contact with the chain rollers when measuring.
If the diameter is less than the minimum, replace the chain and sprocket.
7. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Wrap the chain around the sprocket.
(b) Using vernier caliper, measure the sprocket diameter with the chain wrapped around.
Minimum gear diameter (with chain):
97.3 mm (3.831 in.)
NOTICE:
The vernier caliper must be in contact with the chain rollers when measuring.
If the diameter is less than the minimum, replace the chain and sprocket.
8. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
(a) Wrap the chain around the sprocket.
(b) Using vernier caliper, measure the sprocket diameter with the chain wrapped around.
Minimum gear diameter (with chain):
97.3 mm (3.831 in.)
NOTICE:
The vernier caliper must be in contact with the chain rollers when measuring.
If the diameter is less than the minimum, replace the chain and sprocket.
9. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
(a) Wrap the chain around the timing sprocket.
(b) Using vernier caliper, measure the timing gear diameter with the chain wrapped around.
Minimum gear diameter (with chain):
51.6 mm (2.031 in.)
NOTICE:
The vernier caliper must be in contact with the chain rollers when measuring.
If the gear diameter is less than the minimum, replace the chain sub-assembly and crankshaft timing sprocket.
10. INSPECT CHAIN TENSIONER SLIPPER
(a) Using vernier caliper, measure the tensioner slipper wear.
Maximum wear:
1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the chain tensioner slipper.
11. INSPECT NO. 1 CHAIN VIBRATION DAMPER
(a) Using vernier caliper, measure the vibration damper wear.
Maximum wear:
1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the No. 1 chain vibration damper.
12. INSPECT CHAIN TENSIONER PLATE
(a) Using vernier caliper, 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 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 heights.
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 any of the cam lobe heights are less than the minimum, replace the camshaft.
(c) Inspect the camshaft journals.
(1) Using a micrometer, measure the journal diameter.
Standard journal diameter:
If the journal diameter is not as specified, check the oil clearance.
15. INSPECT NO. 2 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 heights.
Standard cam lobe height:
45.983 to 46.083 mm (1.8104 to 1.8143 in.)
Minimum cam lobe height:
45.873 mm (1.8060 in.)
If any of the cam lobe heights are less than the minimum, replace the camshaft.
(c) Inspect the camshaft journals.
(1) Using a micrometer, measure the journal diameter.
Standard journal diameter:
If the journal diameter is not as specified, check the oil clearance.