Part 2

2UZ-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION

INSPECTION (Continued)

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.

16. INSPECT VALVE LIFTER

(a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
Lifter bore diameter:
31.000 to 31.016 mm (1.2205 to 1.2211 in.)

(b) Using a micrometer, measure the lifter diameter where the distance from the top surface is 12.3 to 12.7 mm (0.484 to 0.500 in.).
Lifter diameter:
30.968 to 30.976 mm (1.2192 to 1.2195 in.)
(c) Subtract the lifter diameter measurement from the lifter bore diameter measurement.
Standard oil clearance:
0.024 to 0.050 mm (0.0009 to 0.0020 in.)
Maximum oil clearance:
0.07 mm (0.0028 in.)
If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head.
17. INSPECT CAMSHAFT OIL CLEARANCE

(a) Install the camshaft timing tube to the camshaft Reassembly.
(b) Clean the bearing caps and camshaft journals.
(c) Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cylinder head as a set.
(d) Place the camshafts on the cylinder head.
(e) Lay a strip of Plastigage across each of the camshaft journals.

(f) Install the bearing caps Reassembly.
For bolt A - Torque: 7.5 Nm (76 kgf-cm, 66 ft-lbf)
For others - Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)

NOTE: Do not turn the camshaft.

(g) Remove the bearing caps.

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

Maximum oil clearance:

If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
(i) Remove the camshafts.
(j) Completely remove the Plastigage.
18. INSPECT CAMSHAFT THRUST CLEARANCE

(a) Install the camshaft Reassembly.
(b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance:

Maximum thrust clearance:

If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
(c) Remove the camshafts.
(d) Remove the camshaft timing tube from the intake camshaft.
19. INSPECT CAMSHAFT GEAR BACKLASH

(a) Install the drive gear to the camshaft timing tube Reassembly.
(b) Install the camshaft timing tube to the intake camshaft Reassembly.
(c) Install the camshafts without installing the exhaust camshaft sub-gear No. 3 and front bearing cap Reassembly.
(d) Using a dial indicator, measure the backlash.
Standard backlash:
0.020 to 0.200 mm (0.0008 to 0.0079 in.)
Maximum backlash:
0.30 mm (0.0118 in.)
If the backlash is greater than the maximum, replace the intake camshaft drive gear and exhaust camshaft.
(e) Remove the camshafts.
(f) Remove the camshaft timing tube from the intake camshaft.
(g) Remove the drive gear from the camshaft timing tube.
20. CLEAN CYLINDER BLOCK SUB-ASSEMBLY

(a) Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
(b) Using a soft brush and solvent, thoroughly clean the cylinder block.
21. INSPECT CYLINDER BLOCK SUB-ASSEMBLY

(a) Inspect for warpage.
(1) Using a precision straight edge and feeler gauge, measure the warpage of the contact surfaces of the cylinder head and crankshaft bearing cap.
Maximum warpage:
0.07 mm (0.0028 in.)
If warpage is greater than the maximum, replace the cylinder block sub-assembly.

(b) Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 8 cylinders and replace all the 8 pistons. If necessary, replace the cylinder block.
(c) Inspect the cylinder bore diameter.

HINT: There are 3 sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block.

(1) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
Standard diameter:

Maximum diameter:
94.230 mm (3.5917 in.)
If the diameter is greater than the maximum, rebore all the 8 cylinders and replace all the 8 pistons. If necessary, replace the cylinder block.

(d) Remove the cylinder ridge.
If the wear is less than 0.2mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.
22. INSPECT PISTON
(a) Clean the piston.

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

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

(3) Using solvent and a brush, thoroughly clean the piston.

NOTE: Do not use a wire brush.

(b) Inspect the piston oil clearance.

HINT: There are 3 sizes of the standard piston diameter, marked "1", "2" or "3" accordingly. The mark is stamped on the piston top.

(1) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.75 mm (1.2106 in.) from the piston head.
Piston diameter:

(2) Measure the cylinder bore diameter in the thrust directions.
(3) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance:
0.090 to 0.111 mm (0.0035 to 0.0044 in.)
Maximum oil clearance:
0.13 mm (0.0051 in.)
If the oil clearance is greater than the maximum, replace all the 8 pistons and rebore all the 8 cylinders. If necessary, replace the cylinder block.

HINT:
Use a new cylinder block:
- Use a piston with the same number mark as the cylinder diameter marked on the cylinder block.
- The shape of the piston varies for the LH and RH banks. The LH piston is marked with 1 cavity and "2", the RH piston with 2 cavities and "2".

(c) Inspect the piston pin fit.
(1) Heat the piston to approx. 60° C (140° F), and push the piston pin into the piston pin hole with your thumb.

(d) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 to 22.006 mm (0.8660 to 0.8664 in.)

23. INSPECT PISTON RING SET

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

If the clearance is not as specified, replace the piston.
(b) Inspect the piston ring end gap.

(1) Insert the piston ring into the cylinder bore.
(2) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 105 mm (4.13 in.) from the top of the cylinder block.

(3) 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, rebore all the 8 cylinders or replace the cylinder block sub-assembly.
24. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) Using a rod aligner and feeler gauge, check the connecting rod alignment.

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

(2) Check for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than the maximum, replace the connecting rod sub-assembly.
(b) Inspect the piston pin oil clearance.

(1) Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing inside diameter:
22.005 to 22.014 mm (0.8663 to 0.8667 in.)

(2) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 to 22.006 mm (0.8660 to 0.8664 in.)
(3) Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance:
0.05 mm (0.0020 in.)
If the oil clearance is greater than the maximum, replace the connecting rod sub-assembly. If necessary, replace the piston and piston pin as a set.
25. REMOVE CONNECTING ROD SMALL END BUSH

(a) Using SST and a press, press out the bushing.
SST: 09222-30010
26. INSTALL CONNECTING ROD SMALL END BUSH

(a) Align the oil holes of a new bushing and the connecting rod.

(b) Using SST and a press, press in the bushing.
SST: 09222-30010

(d) Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
27. INSPECT CONNECTING ROD BOLT

(a) Using vernier calipers, measure the tension portion diameter of the connecting rod bolt.
Standard diameter:
7.200 to 7.300 mm (0.2835 to 0.2874 in.)
Minimum diameter:
7.00 mm (0.2756 in.)
If the diameter is less than the minimum, replace the bolt.
28. INSPECT CRANKSHAFT BEARING CAP BOLT

(a) Using vernier calipers, measure the thread outside diameter of the crankshaft bearing cap bolt.
Standard diameter:
10.760 to 10.970 mm (0.4236 to 0.4319 in.)
Minimum diameter:
10.40 mm (0.4094 in.)
If the diameter is less than the minimum, replace the cap bolt.
29. INSPECT CRANKSHAFT

(a) Inspect for circle runout.
(1) Place the crankshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout:
0.04 mm (0.0016 in.)
If the circle runout is greater than the maximum, replace the crankshaft.

(b) Inspect the crankshaft journals and crank pins.
(1) Using a micrometer, measure the diameter of each crankshaft journal and crank pin.
Crankshaft journal diameter:
66.988 to 67.000 mm (2.6373 to 2.6378 in.)
Crank pin diameter:
51.982 to 52.000 mm (2.0465 to 2.0472 in.)
If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.
(2) Check each crankshaft journal and crank pin for taper and out-of-round as shown in the illustration.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.