Part 1

2UZ-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION

INSPECTION

HINT:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets, O-rings and oil seals with new ones.

1. INSPECT TIMING BELT

NOTICE:
- Do not bend, twist or turn the timing belt inside out.
- Do not allow the timing belt to come into contact with oil, water or steam.
- Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley.

If there are any defects as shown in the illustration, check the following points:

(a) If premature parting occurs, check the following:
- Check for proper installation.
- Check the timing cover gasket for damage and proper installation.

(b) If the belt teeth are cracked or damaged, inspect the camshaft.
(c) If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and water pump.
(d) If there is wear or damage on only one side of the belt, check the belt guide and alignment of each pulley.
(e) If there is noticeable wear on the belt teeth, check for damage on the timing belt or foreign objects on the pulley teeth. Check if the gasket is installed correctly.
If necessary, replace the timing belt.
2. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Visually check the seal portion of the tensioner for oil leakage.

HINT:
If there is a faint trace of oil on the seal on the push rod side, the tensioner is all right.
If leakage is found, replace the tensioner.

(b) Hold the tensioner by hands and push the push rod strongly as shown in the illustration to check that it does not move.
If the push rod moves, replace the tensioner.

NOTE: Do not face the tensioner push rod downward.

(c) Measure the protrusion of the push rod from the housing end.
Protrusion:
11.2 to 12.2 mm (0.440 to 0.480 in.)
If the protrusion is not as specified, replace the tensioner.
3. INSPECT TIMING BELT IDLER

(a) Visually check the seal portion of the idler pulley for oil leakage.
If leakage is found, replace the idler pulley.
(b) Check that the idler pulley turns smoothly.
If necessary, replace the idler.
4. INSPECT CYLINDER HEAD SET BOLT

(a) Using vernier calipers, measure the thread outside diameter of the bolt.
Standard outside diameter:
9.810 to 9.960 mm (0.3862 to 0.3921 in.)
Minimum outside diameter:
9.700 mm (0.3819 in.)
5. INSPECT CAMSHAFTS

(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:
0.08 mm (0.0031 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
41.94 to 42.04 mm (1.6512 to 1.6551 in.)
Exhaust
41.96 to 42.06 mm (1.6520 to 1.6559 in.)
Minimum cam lobe height:
Intake
41.79 mm (1.6453 in.)
Exhaust
41.81 mm (1.6461 in.)
If the cam lobe height is less than the minimum, replace the camshaft.

(c) Inspect the camshaft journals.
(1) Using a micrometer, measure the journal diameter.
Journal diameter:
26.954 to 26.970 mm (1.0612 to 1.0618 in.)
If the journal diameter is not as specified, check the oil clearance.
6. INSPECT CAMSHAFT TIMING TUBE ASSEMBLY

(a) Using a micrometer, measure the journal diameter.
Journal diameter:
39.955 to 39.964 mm (1.5730 to 1.5734 in.)
If the journal diameter is not as specified, check the oil clearance.

(b) Install the timing tube to the intake camshaft, and check that the timing tube turns smoothly.
If necessary, replace the timing tube and intake camshaft.
7. INSPECT CAMSHAFT GEAR SPRING

(a) Using vernier calipers, measure the gap distance of the gear spring.
Gap distance:
18.2 to 18.8 mm (0.717 to 0.740 in.)
If the gap distance is not as specified, replace the gear spring.
8. INSPECT CYLINDER HEAD SUB-ASSEMBLY
(a) Clean the cylinder head.

(1) Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.

NOTE: Be careful not to scratch the cylinder block contact surface.

(2) Using a wire brush, remove all the carbon from the combustion chambers.

NOTE: Be careful not to scratch the cylinder block contact surface.

(3) Using a valve guide bushing brush and solvent, clean all the guide bushes.

(4) Using a soft brush and solvent, thoroughly clean the cylinder head.

(b) Inspect for warpage.
(1) Using a precision straight edge and feeler gauge, measure the warpage of the contact surfaces of the cylinder block and the manifolds.
Maximum warpage:
0.10 mm (0.0039 in.)
If warpage is greater than the maximum, replace the cylinder head.

(c) Inspect for cracks.
(1) Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.
9. INSPECT VALVE

(a) Clean the valves.
(1) Using a gasket scraper, chip off any carbon from the valve head.
(2) Using a wire brush, thoroughly clean the valve.

(b) Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter:
Intake
5.470 to 5.485 mm (0.2154 to 0.2159 in.)
Exhaust
5.465 to 5.480 mm (0.2152 to 0.2157 in.)

(c) Check the valve face angle.
(1) Grind the valve enough to remove pits and carbon.
(2) Check that the valve is ground to the correct valve face angle.
Valve face angle:
44.5°

(d) Check the valve head margin thickness.
Standard margin thickness:
Intake
1.25 mm (0.049 in.)
Exhaust
1.4 mm (0.055 in.)
Minimum margin thickness
0.5 mm (0.020 in.)
If the margin thickness is less than the minimum, replace the valve.

(e) Check the valve overall length.
Standard overall length:
Intake
95.05 mm (3.7421 in.)
Exhaust
95.10 mm (3.7441 in.)
Minimum overall length:
Intake
94.55 mm (3.7224 in.)
Exhaust
94.60 mm (3.7244 in.)
If the overall length is less than the minimum, replace the valve.

(f) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.

NOTE: Do not grind off more than the minimum.

10. INSPECT VALVE SPRING

(a) Using a steel square, measure the deviation of the valve spring.
Maximum deviation:
2.0 mm (0.079 in.)
If the deviation is greater than the maximum, replace the valve spring.

(b) Using vernier calipers, measure the free length of the valve spring.
Free length:
54.1 mm (2.130 in.)
If the free length is not as specified, replace the valve spring.

(c) Using a spring tester, measure the tension of the valve spring at the specified installed length.
Installed tension:
210 to 226 N (21.4 to 23.0 kgf, 47.2 to 50.7 lbf) at 35.0 mm (1.378 in.)
If the installed tension is not as specified, replace the valve spring.
11. INSPECT VALVE GUIDE BUSH

(a) Using a caliper gauge, measure the inside diameter of the guide bush.
Bush inside diameter:
5.510 to 5.530 mm (0.2169 to 0.2177 in.)
(b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.
Standard oil clearance:
Intake
0.025 to 0.060 mm (0.0010 to 0.0024 in.)
Exhaust
0.030 to 0.065 mm (0.0012 to 0.0026 in.)
Maximum oil clearance:
Intake
0.08 mm (0.0031 in.)
Exhaust
0.10 mm (0.0039 in.)
If the clearance is greater than the maximum, replace the valve and guide bush.
12. REMOVE VALVE GUIDE BUSH

(a) Gradually heat the cylinder head to 80 to 100°C (176 to 212°F).

(b) Using SST and a hammer, tap out the guide bush.
SST: 09201-10000
09201-01060
SST: 09950-70010
09951-07100
13. INSTALL VALVE GUIDE BUSH

(a) Using a caliper gauge, measure the bush bore diameter of the cylinder head.

(b) Select a new guide bush (STD or O/S 0.05).

If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore so that the dimension is between 10.335 and 10.356 mm (0.4069 and 0.4077 in.).
If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

HINT: Different bushes are used for the intake and exhaust.

(c) Gradually heat the cylinder head to 80 to 100°C (176 to 212°F).
(d) Using SST and a hammer, tap in a new guide bush to the specified protrusion height.
Protrusion height:
Intake
9.2 to 9.8 mm (0.362 to 0.386 in.)
Exhaust
8.2 to 8.8 mm (0.323 to 0.346 in.)
SST: 09201-01055
SST: 09950-70010
09951-07100

(e) Using a sharp 5.5mm reamer, ream the guide bush to obtain the specified clearance between the guide bush and valve stem.
SST: 09201-10000
09201-01060
SST: 09950-70010
09951-07100
14. INSPECT VALVE SEAT

(a) Using a 45° carbide cutter, resurface the valve seats. Clean metal filings from the valve seats.

(b) Check the valve seating position.
(1) Apply a light coat of prussian blue (or white lead) to the valve face.
(2) Lightly press the valve against the seat. Do not rotate valve.
(c) Check the valve face and seat for the following:
(1) If prussian blue appears around the entire face, the valve is centered. If not, replace the valve.
(2) If prussian blue appears around the entire valve seat, the guide and face are centered. If not, resurface the seat.
(3) Check that the seat contacts in the middle of the valve face with the following width:
Width:
1.0 to 1.4 mm (0.039 to 0.055 in.)
15. REPAIR VALVE SEAT

(a) If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.

(b) If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.