Part 2

2UZ-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

Part 2

Continued From Part 1 Part 1

36. REMOVE SPARK PLUG TUBE GASKET

(a) Bend the 4 ventilation case claws installed on the cylinder head cover to an angle of 90° or more.
(b) Using a screwdriver, pry out the gasket.

NOTE: Be careful not to damage the cylinder head cover. Tape the screwdriver tip.

37. REMOVE CAMSHAFT TIMING TUBE ASSEMBLY

(a) Mount the hexagonal portion of the camshaft in a vise.

NOTICE:
- Be careful not to damage the camshaft.
- Do not remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the timing tube assembly with a new one.

(b) Remove the screw plug and seal washer.
(c) Using a 10 mm hexagon wrench, and remove the bolt.
(d) Pull out the timing tube and drive gear assembly from the camshaft.

(e) Using SST and a 5 mm hexagon wrench, remove the 4 bolts, drive gear and oil seal.
SST: 09960-10010
09962-01000
09963-00500

NOTE: Be careful not to damage the timing tube.

38. REMOVE CAMSHAFT SUB GEAR

(a) Mount the hexagonal portion of the camshaft in a vise.

NOTE: Be careful not to damage the camshaft.

(b) Using SST, turn the sub gear clockwise, and remove the service bolt.
SST: 09960-10010
09962-01000
09963-00500

(c) Using snap ring pliers, remove the snap ring.
(d) Remove the wave washer, sub gear and gear spring.

HINT: Arrange the camshaft sub gears and gear spring (RH and LH sides).

39. REMOVE OIL PUMP SEAL

(a) Using a screwdriver, pry out the oil seal.

NOTE: Be careful not to damage the oil pump body. Tape the screwdriver tip.

40. REMOVE ENGINE REAR OIL SEAL

(a) Using a screwdriver and hammer, tap out the oil seal.
41. REMOVE VALVE LIFTER
(a) Remove the valve lifter and adjusting shim.

HINT: Arrange the valve lifters and shims in the correct order.

42. REMOVE INTAKE VALVE

(a) Using SST, compress the valve spring and remove the 2 valve spring retainer locks.
SST: 09202-70020
09202-00010
(b) Remove the spring retainer, valve spring, valve and spring seat.

HINT: Arrange the valves, valve springs, spring seats and spring retainers in the correct order.

43. REMOVE EXHAUST VALVE

(a) Using needle-nose pliers, remove the oil seal.
45. INSPECT CONNECTING ROD THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance:
0.160 to 0.290 mm (0.0063 to 0.0114 in.)
Maximum thrust clearance:
0.35 mm (0.0138 in.)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
Connecting rod thickness (Reference):
22.880 to 22.920 mm (0.9008 to 0.9024 in.)
46. INSPECT CONNECTING ROD OIL CLEARANCE

(a) Check the matchmarks on the connecting rod and cap to ensure correct reassembly.
(b) Remove the 2 connecting rod cap bolts.

(c) Using the removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

HINT: Keep the lower bearing inserted with the connecting rod cap.

(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

(f) Lay a strip of Plastigage across the crank pin.

(g) Match the numbered connecting rod cap with the connecting rod.
(h) Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.

(i) Check that the outside mark of the connecting rod cap is facing in the correct direction.

HINT:
- The connecting rod cap bolts are tightened in 2 progressive steps.
- If any one of the connecting rod cap bolts is broken or deformed, replace it.

(j) Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts.
(k) Install and alternately tighten the 2 connecting rod cap bolts in several steps.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)

NOTE:
Do not turn the crankshaft.
If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.

(l) Mark the front of the connecting cap bolts with paint.
(m) Retighten the cap bolts 90° as shown in the illustration.
(n) Check that the painted mark is now at a 90° angle to the front.

(o) Remove the 2 bolts, connecting rod cap and lower bearing.

(p) Measure the Plastigage at its widest point.
Standard oil clearance:
0.021 to 0.047 mm (0.0008 to 0.0019 in.)
Maximum oil clearance:
0.065 mm (0.0026 in.)
If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

HINT: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, add together the numbers imprinted on the connecting rod cap and crankshaft, then select the bearing with the same number as the total. There are 6 sizes of standard bearings, marked "2", "3", "4", "5", "6" and "7".

EXAMPLE: Connecting rod cap "3" + Crankshaft "1" = Total number 4 (Use bearing "4")

(q) Completely remove the Plastigage.
47. REMOVE PISTON AND CONNECTING ROD

(a) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

HINT:
- Keep the bearings, connecting rod and cap together.
- Arrange the piston and connecting rod assemblies in the correct order.

48. REMOVE PISTON

(a) Check the fitting condition between the piston and piston pin.
(1) Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.

(b) Using a piston ring expander, remove the 2 piston rings.
(c) Remove the oil ring (2 side rails and expander) by hand.

HINT: Arrange the piston rings in the correct order.

(d) Using a screwdriver, pry out the 2 snap rings.

(e) Gradually heat the piston to approx. 60°C (140°F).

(f) Using a plastic hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.

HINT:
- The piston and pin are a matched set.
- Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

49. INSPECT CRANKSHAFT THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 to 0.220 mm (0.0008 to 0.0087 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.

50. INSPECT CRANKSHAFT OIL CLEARANCE

(a) Uniformly loosen and remove the 10 crankshaft bearing cap bolts in several steps, in the order shown in the illustration.

(b) Using 2 screwdrivers, pry out the crankshaft bearing cap, and remove the 5 crankshaft bearing caps, 5 lower bearings and 2 lower thrust washers (No. 3 crankshaft bearing cap only).

NOTE:
Be careful not to damage the cylinder block.
- Keep the lower bearing and crankshaft bearing cap together.
- Arrange the crankshaft bearing caps and lower thrust washers in the correct order.

(c) Lift out the crankshaft.
(d) Remove the 2 upper thrust washers.

HINT:
- Arrange the upper thrust washers in the correct order.
- Keep the upper bearings together with the cylinder block.

(e) Clean each crankshaft journal and bearing.
(f) Check each crankshaft journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

(g) Place the crankshaft on the cylinder block.
(h) Lay a strip of Plastigage across each journal.

(i) Install the 5 crankshaft bearing caps in their proper locations.

HINT:
- The crankshaft bearing cap bolts are tightened in 2 progressive steps (Procedures "A" and "B").
- If any one of the main bearing cap bolts is broken or deformed, replace it.

(j) Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts.
(k) Install and uniformly tighten the 10 crankshaft bearing cap bolts in several steps, in the order shown in the illustration (Procedure "A").
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)

NOTE:
Do not turn the crankshaft.
If any one of the crankshaft bearing cap bolts does not meet the torque specification, replace the crankshaft bearing cap bolt.

(l) Mark the front of the crankshaft bearing cap bolts with paint.
(m) Retighten the crankshaft bearing cap bolts by 90° in the order shown (Procedure "B").
(n) Check that the painted mark is now at a 90° angle to the front.
(o) Remove the crankshaft bearing caps.

(p) Measure the Plastigage at its widest point.
Standard clearance:

Maximum clearance:

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

HINT: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, add together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of the standard bearings. For No. 1 and No. 5 position bearings, use bearings marked "3", "4", "5", "6" and "7". For the other position bearings, use bearings marked "1", "2", "3", "4" and "5".

EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "5")

EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "3")

(q) Completely remove the Plastigage.
51. REMOVE CRANKSHAFT
(a) Lift up the crankshaft.
(b) Remove the 5 upper crankshaft bearings and 2 upper thrust washers from the cylinder block.

HINT: Arrange the crankshaft bearing caps, bearings and thrust washers in the correct order.

52. REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY