Engine Unit

2AZ-FXE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION

1. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

(a) Check the lock of the camshaft timing gear.

Text in Illustration

(1) Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked.

NOTICE:
Be careful not to damage the camshaft.

(b) Release the lock pin.

(1) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

HINT
The 2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece.

(2) Prick a hole in the tape on the advance side path and the retard side path opposite to the advance side path hole as shown in the illustration.

(3) Apply approximately 150 kPa (1.5 kgf/cm2, 22 psi) of air pressure to the two broken paths.

Text in Illustration

CAUTION:
Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.

(4) Check that the camshaft timing gear advances when reducing the air pressure applied to the retard side path.

OK:

Gear rotates in the advance direction.

HINT
This operation releases the lock pin for the most retarded position.

(5) When the camshaft timing gear reaches the most advanced position, release air pressure from the retard side path and advance side path, in that order.

NOTICE:
Do not release air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

(c) Check for smooth rotation.

(1) Rotate the camshaft timing gear within its movable range several times, but do not turn it to the most retarded position. Check that the gear rotates smoothly.

OK:

Gear rotates smoothly.

NOTICE:
Do not use an air gun to check for smooth operation.

(d) Check the lock in the most retarded position.

(1) Confirm that the camshaft timing gear is locked at the most retarded position.

2. 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 (0.00118 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 height.

Standard cam lobe height:

45.363 to 45.463 mm (1.7859 to 1.7899 in.)

Minimum cam lobe height:

45.253 mm (1.7816 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.

Standard Journal Diameter:

If the journal diameter is not as specified, check the oil clearance.

3. INSPECT NO. 2 CAMSHAFT

(a) Inspect the camshaft for runout.

(1) Using a micrometer, measure the cam lobe height.

Standard cam lobe height:

46.063 to 46.163 mm (1.8135 to 1.8174 in.)

Minimum cam lobe height:

45.953 mm (1.8092 in.)

If the cam lobe height is less than the minimum, replace the No. 2 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.

4. 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 (0.00197 to 0.00354 in.)

Maximum thrust clearance:

0.09 mm (0.00354 in.)

If the thrust clearance is greater than the maximum, replace the balanceshaft housing and bearings. If necessary, replace the balanceshaft.

5. 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 Reassembly.

(d) Lay a strip of Plastigage across each journal.

Text in Illustration

(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.

Text in Illustration

Standard oil clearance:

0.022 to 0.049 mm (0.000866 to 0.00193 in.)

Maximum oil clearance:

0.049 mm (0.00193 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.

Text in Illustration

Standard Balanceshaft Housing Journal Bore Diameter:

Standard Bearing Center Wall Thickness:

Standard balanceshaft journal diameter:

22.985 to 23.000 mm (0.9049 to 0.9055 in.)

6. INSPECT BALANCESHAFT HOUSING BOLT

(a) Using a vernier caliper, measure the length of the balanceshaft housing bolts from the seat to the end.

Text in Illustration

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.

7. INSPECT CHAIN SUB-ASSEMBLY

(a) Pull the chain sub-assembly with a force of 140 N (14 kgf, 31.5 lbf) as shown in the illustration.

Text in Illustration

(b) Using a 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 average elongation is greater than the maximum, replace the chain sub-assembly.

8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY

(a) Pull the No. 2 chain sub-assembly with a force of 140 N (14 kgf, 31.5 lbf) as shown in the illustration.

Text in Illustration

(b) Using a 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 average elongation is greater than the maximum, replace the No. 2 chain sub-assembly.

9. INSPECT OIL PUMP DRIVE GEAR

(a) Place the No. 2 chain sub-assembly around the oil pump drive gear.

(b) Using a vernier caliper, measure the diameter of the oil pump drive gear and No. 2 chain sub-assembly.

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 No. 2 chain sub-assembly and oil pump drive gear.

10. INSPECT OIL PUMP DRIVE SHAFT GEAR

(a) Place the No. 2 chain sub-assembly around the oil pump drive shaft gear.

(b) Using a vernier caliper, measure the diameter of the oil pump drive shaft gear and No. 2 chain sub-assembly.

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 No. 2 chain sub-assembly and oil pump drive shaft gear.

11. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

(a) Place the chain sub-assembly around the camshaft timing gear assembly.

(b) Using a vernier caliper, measure the diameter of the camshaft timing gear assembly and chain sub-assembly.

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 sub-assembly and camshaft timing gear assembly.

12. INSPECT CAMSHAFT TIMING SPROCKET

(a) Place the chain sub-assembly around the camshaft timing sprocket.

(b) Using a vernier caliper, measure the diameter of the camshaft timing sprocket and chain sub-assembly.

Minimum sprocket 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 sub-assembly and camshaft timing sprocket.

13. INSPECT CRANKSHAFT TIMING GEAR

(a) Place the chain sub-assembly around the crankshaft timing gear.

(b) Using a vernier caliper, measure the diameter of the crankshaft timing gear and chain sub-assembly.

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 diameter is less than the minimum, replace the chain sub-assembly and crankshaft timing gear.

14. INSPECT CHAIN TENSIONER SLIPPER

(a) Using a vernier caliper, measure the chain tensioner slipper wear.

Maximum wear:

1.0 mm (0.0394 in.)

If the wear is greater than the maximum, replace the chain tensioner slipper.

15. INSPECT NO. 1 CHAIN VIBRATION DAMPER

(a) Using a vernier caliper, measure the No. 1 chain vibration damper wear.

Maximum wear:

1.0 mm (0.0394 in.)

If the wear is greater than the maximum, replace the No. 1 chain vibration damper.

16. INSPECT CHAIN TENSIONER PLATE

(a) Using a vernier caliper, measure the chain tensioner plate wear.

Maximum wear:

0.5 mm (0.0197 in.)

If the wear is greater than the maximum, replace the chain tensioner plate.

17. INSPECT NO. 1 CHAIN TENSIONER

(a) Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.

Text in Illustration

(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.

18. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

(a) Using a precision straightedge and feelergauge, measure the surface contacting the exhaust manifold converter sub-assembly for warpage.

Maximum warpage:

0.70 mm (0.0276 in.)

If the warpage is greater than the maximum, replace the exhaust manifold converter sub-assembly.