Engine Unit

2UZ-FE ENGINE MECHANICAL: ENGINE UNIT:

INSPECTION

1. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head.
Maximum warpage:
0.50 mm (0.0197 in.)
If the warpage is greater than the maximum, replace the exhaust manifold.
2. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Using a vernier caliper, measure the thread outside diameter of the bolt.
Measuring point:

Standard outside diameter:
9.810 to 9.960 mm (0.386 to 0.392 in.)
Minimum outside diameter:
9.700 mm (0.382 in.)
If the outside diameter is less than the minimum, replace the set bolt.

HINT: If a visual check reveals no excessively thin areas, check the center of the bolt (see illustration) and find the area that has the lowest diameter.

4. INSPECT CAMSHAFT SUB-ASSEMBLY

(a) Inspect the circle 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:

Minimum cam lobe height:

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:
26.954 to 26.970 mm (1.061 to 1.062 in.)
If the journal diameter is not as specified, check the oil clearance.

(2) Using a micrometer, measure the journal diameter for the camshaft timing tube.
Standard journal diameter:
30.984 to 31.000 mm (1.2198 to 1.2204 in.)
5. INSPECT CAMSHAFT TIMING TUBE ASSEMBLY

(a) Using a micrometer, measure the journal diameter.
Standard 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. If necessary, replace the camshaft and cylinder head.
(b) Install the camshaft timing tube to the camshaft (Reassembly).
(c) Check the lock of the camshaft timing tube.
(1) Check that the camshaft timing tube is locked.
(d) Release the lock pin.

(1) Clean the camshaft timing tube journal with non-residue solvent.
(2) Wrap tape around the entire journal to block the 4 oil holes as shown in the illustration.
(3) Open a hole in the tape at 2 places, one in the retard side oil hole and one in the advance side oil hole as shown in the illustration.

(4) Apply approximately 200 kPa (2.0 kgf/cm2, 29 psi) of air pressure to the 2 open oil holes (the advance side oil hole and the retard side oil hole).

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

HINT: The lock pin will be released when air pressure is applied.

(5) Check that the camshaft timing tube revolves in the advance direction when reducing the air pressure applied to the retard side oil hole.
(6) When the camshaft timing tube reaches the most advanced position, release the air pressure from the retard side oil hole and advance side oil hole, in that order.

NOTICE:
- Do not release the air pressure from the advance side oil hole first. The tube may abruptly shift in the retard direction and break the lock pin.
- When releasing the air pressure from the retard side oil hole, do not release the air pressure too quickly to prevent damage.

(e) Check for smooth rotation.
(1) Apply 60 kPa (0.6 kgf/cm2, 8.7 psi) of air pressure to the retard side oil hole to release the lock pin.
(2) Turn the camshaft timing tube within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the camshaft timing tube turns smoothly.

NOTE: Do not use air pressure to perform the smooth rotation check. Always perform the check by hand.

(f) Check the lock in the most retarded position.
(1) Confirm that the camshaft timing tube is locked at the most retarded position.
(g) Remove the camshaft timing tube (Disassembly).
6. INSPECT CAMSHAFT GEAR SPRING

(a) Using a vernier caliper, measure the gap distance of the gear spring.
Standard 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.
7. INSPECT CAMSHAFT OIL CLEARANCE

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

HINT:
- for Bank 1, refer to the following procedures (Installation).
- for Bank 2, refer to the following procedures (Installation).

NOTE: Do not turn the camshaft.

(f) Remove the bearing caps.

HINT:
- for Bank 1, refer to the following procedures (Removal).
- for Bank 2, refer to the following procedures (Removal).

(g) 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 cylinder head sub-assembly.
(h) Remove the camshafts.
(i) Completely remove the Plastigage.
8. INSPECT VALVE CLEARANCE (Adjustments)

9. INSPECT TIMING BELT (Testing and Inspection)

10. INSPECT TIMING BELT TENSIONER ASSEMBLY (Testing and Inspection)

11. INSPECT NO. 1 TIMING BELT IDLER SUB-ASSEMBLY (Testing and Inspection)

12. INSPECT CYLINDER HEAD SUB-ASSEMBLY (Testing and Inspection)

13. INSPECT VALVE LIFTER (Testing and Inspection)

14. INSPECT CAMSHAFT THRUST CLEARANCE (Testing and Inspection)

15. INSPECT CAMSHAFT GEAR BACKLASH (Testing and Inspection)

16. INSPECT CYLINDER BLOCK SUB-ASSEMBLY (Testing and Inspection)