Part 2

2TR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (Continued)

31. INSPECT VALVE GUIDE BUSHING

(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:

0.025 to 0.060 mm (0.0010 to 0.0024 in.) (Intake)

0.030 to 0.065 mm (0.0012 to 0.0026 in.) (Exhaust)

Maximum oil clearance:

0.08 mm (0.0032 in.) (Intake)

0.10 mm (0.0039 in.) (Exhaust)

HINT
* If the clearance is greater than the maximum, replace the intake valve and intake guide bush.
* If the clearance is greater than the maximum, replace the exhaust valve and exhaust guide bush.
32. 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:

0.150 to 0.350 mm (0.0059 to 0.0138 in.)

Maximum thrust clearance:

0.40 mm (0.016 in.)

(b) If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.

33. INSPECT CONNECTING ROD OIL CLEARANCE

(a) Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly.

HINT
The matchmarks on the connecting rods and caps are for ensuring the correct reassembly.

(b) Remove the 2 connecting rod cap bolts.

(c) Using the 2 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 to the connecting rod cap.

(d) Clean the crank pin and bearing.

(e) Check the crank pin and bearing for pitting and scratches.

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

(g) Check that the front mark of the connecting rod cap is facing forward.

(h) Install the connecting rod cap.

NOTICE:
Do not turn the crankshaft.

(i) Remove the 2 bolts and connecting rod cap (see steps (b) and (c) above).

(j) Measure the Plastigage at its widest point.

Standard oil clearance:

0.024 to 0.049 mm (0.0009 to 0.0019 in.)

Maximum oil clearance:

0.066 mm (0.0026 in.)

(k) If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, replace the crankshaft.

HINT
If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2 and 3 mark on its surface.

Reference:

(l) Completely remove the Plastigage.

34. 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.)

(b) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.

Thrust washer thickness:

2.440 to 2.490 mm (0.0961 to 0.0980 in.)

35. CLEAN WITH PIN PISTON SUB-ASSEMBLY

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

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

NOTICE:
Do not use a wire brush.

36. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Check the oil nozzles for damage or clogging.

If necessary, replace the oil nozzle.

37. INSPECT BALANCE SHAFT THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance while moving the balanceshaft back and forth.

Standard thrust clearance:

0.07 to 0.13 mm (0.0027 to 0.0051 in.)

Maximum thrust clearance:

0.20 mm (0.0079 in.)

(b) If the thrust clearance is greater than the maximum, replace the balanceshaft thrust washer. If necessary, replace the balanceshaft.

38. INSPECT CYLINDER BLOCK FOR FLATNESS

(a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.

Maximum warpage:

0.05 mm (0.0020 in.)

(b) If the warpage is greater than the maximum, replace the cylinder block.

(c) Visually check the cylinder for vertical scratches.

(d) If deep scratches are present, rebore all the 4 cylinders. If necessary, replace the cylinder block.

39. INSPECT CYLINDER BORE

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

Standard diameter:

94.990 to 95.003 mm (3.7398 to 3.7403 in.)

Maximum difference diameter:

0.2 mm (0.008 in.)

(a) If the diameter is greater than the maximum, rebore all the 4 cylinders. If necessary, replace the cylinder block.

(b) Inspect the cylinder ridge.

(c) If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.

40. CLEAN CYLINDER BLOCK

(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.

41. INSPECT PISTON DIAMETER

(a) Using a micrometer, measure the piston diameter at right angles to the piston center line, the indicated distance from the piston end.

Distance:

9.3 mm (0.366 in.)

Piston diameter:

94.941 to 94.971 mm (3.7378 to 3.7390 in.) (for standard)

42. INSPECT PISTON OIL CLEARANCE

(a) Measure the cylinder bore diameter in the thrust directions (see step 20).

(b) Subtract the piston diameter measurement from the cylinder bore diameter measurement.

Standard oil clearance:

0.019 to 0.052 mm (0.0007 to 0.0020 in.)

(c) If the oil clearance is greater than the standard, replace all the pistons and rebore all the cylinders. If necessary, replace the cylinder block.

HINT
* Bore all the cylinders for the O/S piston outside diameter.
* Replace all the piston rings with ones to match the O/S pistons.
(d) If the oil clearance is greater than the standard.

(1) Prepare 4 new O/S pistons.

O/S 0.50 piston diameter:

95.441 to 95.451 mm (3.7575 to 3.7579 in.)

(2) Using a micrometer, measure the piston diameter at right angles to the piston center line, the indicated distance from the piston end.

Distance:

9.3 mm (0.366 in.)

(3) Calculate the amount each cylinder is to be rebored as follows:

Size to be rebored = P + C -H:

(4) Bore and hone the cylinders to calculated dimensions.

Maximum honing:

0.02 mm (0.0008 in.)

NOTICE:
Excess honing will destroy the finished roundness.

43. INSPECT RING GROOVE CLEARANCE

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

Ring groove clearance:

(b) If the clearance is not as specified, replace the piston.

44. INSPECT PISTON RING END GAP

(a) Insert the piston ring into the cylinder bore.

(b) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block.

(c) Using a feeler gauge, measure the end gap.

Standard end gap:

Maximum end gap:

(d) 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 4 cylinders or replace the cylinder block.

45. INSPECT PISTON PIN OIL CLEARANCE

(a) Using a caliper gauge, measure the inside diameter of the piston pin hole.

Piston pin hole inside diameter:

22.001 to 22.010 mm (0.8662 to 0.8665 in.)

(b) Using a micrometer, measure the piston pin diameter.

Piston pin diameter:

21.997 to 22.006 mm (0.8660 to 0.8664 in.)

(c) 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.)

(d) Subtract the piston pin diameter measurement from the piton pin hole diameter measurement.

Standard oil clearance:

0.001 to 0.007 mm (0.00004 to 0.00028 in.)

Maximum oil clearance:

0.010 mm (0.0004 in.)

HINT
If the oil clearance is greater than the maximum, replace the piston and piston pin as a set.

(e) 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:

0.025 mm (0.0010 in.)

(f) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin as a set.

46. INSPECT CONNECTING ROD

(a) Using a rod aligner and feeler gauge, check the connecting rod alignment.

(1) Check for bend.

Maximum bend:

0.03 mm (0.0012 in.) per 100 mm (3.94 in.)

(2) If the bend is greater than the maximum, replace the connecting rod sub-assembly.

(3) Check for twist.

Maximum twist:

0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

(4) If the twist is greater than the maximum, replace the connecting rod sub-assembly.

47. INSPECT CONNECTING ROD BOLT

(a) Using vernier calipers, measure the tension portion diameter of the bolt.

Standard diameter:

7.2 to 7.3 mm (0.283 to 0.287 in.)

Minimum diameter:

7.0 mm (0.276 in.)

(b) If the diameter is less than the minimum, replace the bolt.

48. 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:

0.03 mm (0.0012 in.)

(3) If the circle runout is greater than the maximum, replace the crankshaft.

(b) Inspect the main journals.

(1) Using a micrometer, measure the diameter of each main journal.

Standard journal diameter::

(2) If the diameter is not as specified, check the oil clearance (see step 30). If necessary, replace the crankshaft.

(3) Check each main journal for taper and out-of-round as shown in the illustration.

Maximum taper and out-of-round:

0.005 mm (0.0002 in.)

(4) If the taper and out-of-round is greater than the maximum, replace the crankshaft.

(c) Inspect the crank pin.

(1) Using a micrometer, measure the diameter of each crank pin.

Diameter:

52.989 to 53.002 mm (2.0862 to 2.0867 in.)

(2) If the diameter is not as specified, check the oil clearance (see step 2). If necessary, replace the crankshaft.

(3) Check each crank pin for taper and out-of-round as shown in the illustration.

Maximum taper and out-of-round:

0.003 mm (0.0001 in.)

(4) If the taper and out-of-round is greater than the maximum, replace the crankshaft.

49. INSPECT CRANKSHAFT OIL CLEARANCE

HINT
* Keep the lower bearings and crankshaft bearing caps together.
* Arrange the thrust washers in the correct order.
* Keep the upper crankshaft bearings and upper thrust washers together with the cylinder block.
(a) Clean each main journal and bearing.

(b) Check each main journal and bearing for pitting and scratches.

If the journal or bearing is damaged, replace the bearing.

(c) Place the crankshaft on the cylinder block.

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

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

(f) Install the 5 crankshaft bearing caps with the 10 bolts (see step 49).

NOTICE:
Do not turn the crankshaft.

(g) Remove the 10 bolts and 5 crankshaft bearing caps.

(h) Measure the Plastigage at its widest point.

Standard oil clearance:

Maximum oil clearance:

0.10 mm (0.0039 in.)

(i) If the oil clearance is greater than the maximum, replace the crankshaft bearing.

HINT
* If replacing the cylinder block, measure the bearing standard clearance.
* If replacing a bearing, first check the number on the cylinder block for the bearing's respective journal. Then replace the bearing with one that has the same number. Each bearing's standard thickness is indicated by a 1, 2 or 3 mark on its surface.

Reference:

(j) Completely remove the Plastigage.

50. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Using vernier calipers, measure the minimum diameter of the compressed thread at the measuring point.

Standard diameter:

10.76 to 10.97 mm (0.4236 to 0.4319 in.)

Minimum diameter:

10.66 mm (0.4197 in.)

(b) If the diameter is less than the minimum, replace the bolt.

51. INSPECT NO.1 BALANCESHAFT

(a) Inspect the diameter of the journal.

(1) Using a micrometer, measure the diameter of the balanceshaft main journals.

Main journal diameter:

(b) Inspect the diameter of bearing.

(1) Using a cylinder gauge, measure the inside diameter of the balanceshaft bearing.

Bearing inside diameter:

(c) Inspect oil clearance.

(1) Subtract the balanceshaft main journal diameter measurement from the balanceshaft bearing inside diameter measurement.

Standard oil clearance:

Maximum oil clearance:

0.15 mm (0.0059 in.)

(2) If the oil clearance is greater than the maximum, replace the cylinder block and balanceshaft.

52. INSPECT NO.2 BALANCESHAFT

(a) Inspect the diameter of the journal.

(1) Using a micrometer, measure the diameter of the balanceshaft main journals.

Main journal diameter:

(b) Inspect the diameter of bearing.

(1) Using a cylinder gauge, measure the inside diameter of the balanceshaft bearing.

Bearing inside diameter:

Maximum oil clearance:

0.15 mm (0.0059 in.)

(d) If the oil clearance is greater than the maximum, replace the cylinder block and balanceshaft.