2ZR-FE ENGINE MECHANICAL  ENGINE UNIT  INSPECTION  


PROCEDURE

Hide 13801 1.INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

a.
A125485

Turn the roller by hand to check that it turns smoothly.

HINT:

If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.



Hide 13750 2.INSPECT VALVE LASH ADJUSTER ASSEMBLY

NOTICE:
·

Keep the valve lash adjuster assembly free of dirt and foreign matter.

·

Only use clean engine oil.



a.

Place the valve lash adjuster assembly into a container filled with engine oil.


b.
A286731
1.094,0.75 1.573,0.479 true 1.948,0.49 2.417,0.698 true 1,1.198 1.615,0.917 true 1.885,0.938 2.521,1.094 true 1.021,1.448 1.615,1.313 true 1.885,1.313 2.469,1.417 true 0.896,1.844 1.625,1.781 true 1.885,1.781 2.573,1.875 true 0.802,2.313 1.635,2.5 true 1.917,2.5 2.698,2.281 true 0.781,2.771 0.781,2.49 true 2.698,2.76 2.698,2.479 true 1.333,3.333 1.521,2.844 true 1.677,1.229 1.99,1.385 0.313,0.156 10 *f 1.708,2.438 2.021,2.667 0.313,0.229 10 *g 1.688,1.708 2,1.865 0.313,0.156 10 *d 0.729,2.792 1.042,2.948 0.313,0.156 10 *e 0.688,0.229 1,0.385 0.313,0.156 10 *a 2.635,0.229 2.948,0.385 0.313,0.156 10 *b 1.688,0.833 2,0.99 0.313,0.156 10 *c 1.563,2.75 2.021,2.948 0.458,0.198 10 SST 1.625,0.396 2.083,0.594 0.458,0.198 10 SST 2.615,2.792 2.927,2.99 0.313,0.198 10 *e
*a Correct
*b Incorrect
*c Taper Part
*d Low Pressure Chamber
*e High Pressure Chamber
*f Plunger
*g Check Ball


Insert the SST tip into the valve lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

SST
09276-75010  


c.

Squeeze SST and the valve lash adjuster assembly together to move the plunger up and down 5 to 6 times.


d.

Check the movement of the plunger and bleed it.

OK:

Plunger moves up and down.


NOTICE:

When bleeding the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, the high-pressure chamber will not be bled.



e.

After bleeding, remove SST. Then try to quickly and firmly press the plunger with a finger.

OK:

Plunger is very difficult to move.


If the result is not as specified, replace the valve lash adjuster assembly.


Hide 13050 3.INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

a.

Install the camshaft timing gear assembly.

Click hereEngine / Hybrid System>2ZR-FE ENGINE MECHANICAL>CAMSHAFT>INSTALLATION


b.

Check the lock of the camshaft timing gear assembly.

i.

Confirm that the camshaft timing gear assembly is locked.



c.
A313440
1.344,3.281 1.969,2.5 1.969,2.5 1.313,3.125 true 2.698,3.135 2.531,3.135 2.531,3.135 2.042,2.938 true 2.75,3.667 2.583,3.667 2.583,3.667 2.094,3.469 true 0.604,3.656 1.094,3.656 true 2.76,4.208 2.552,4.208 2.552,4.208 1.896,3.583 true 1.052,3.354 0.531,3.177 0.531,3.177 1.052,3.042 true 1.896,0.542 2.208,0.74 0.313,0.198 10 false *c 2,2.406 2.313,2.604 0.313,0.198 10 false *b 2.75,3.042 3.063,3.24 0.313,0.198 10 false *a 2.802,3.583 3.115,3.781 0.313,0.198 10 false *b 0.438,3.583 0.75,3.781 0.313,0.198 10 false *d 2.833,4.125 3.146,4.323 0.313,0.198 10 false *e 0.333,3.083 0.646,3.281 0.313,0.198 10 false *e
*a Open
*b Close
*c Advance Side Path
*d Vinyl Tape
*e Rubber Piece


Release the lock pin.

i.

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

HINT:

There are 4 oil paths in the groove of the camshaft. Plug 3 of the paths with rubber pieces.



ii.

Prick a hole in the tape placed on the advance side path.


iii.
A153834

While applying approximately 150 kPa (1.5 kgf/cm2, 22 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

CAUTION:

Cover the path with a piece of cloth when applying pressure to keep oil from spraying.


NOTICE:

Do not lock the camshaft timing gear assembly. If it is locked, release the lock pin again.


HINT:
·

Depending on the air pressure applied, the camshaft timing gear assembly may be turned in the advance direction without applying any force.

·

If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.





d.

Check for smooth rotation.

i.

Turn the camshaft timing gear assembly within its movable range (20.5 to 22.5°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the camshaft timing gear assembly turns smoothly.

NOTICE:

Do not lock the camshaft timing gear assembly. If it is locked, release the lock pin again.




Hide 13070A 4.INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

a.

Install the camshaft timing exhaust gear assembly.

Click hereEngine / Hybrid System>2ZR-FE ENGINE MECHANICAL>CAMSHAFT>INSTALLATION


b.

Check the lock of the camshaft timing exhaust gear assembly.

i.

Make sure that the camshaft timing exhaust gear assembly is locked.



c.
A152653
1.969,4.354 1.896,4.354 1.896,4.354 1.719,3.896 true 1.396,3.406 1.125,4.396 1.125,4.396 1.948,3.01 true 0.771,3.5 0.917,3.5 0.917,3.5 1.365,3.25 true 0.802,2.958 0.896,2.958 0.896,2.958 1.365,2.781 true 2.604,3.354 2.51,3.354 2.51,3.354 2.094,3.104 true 2.552,3.052 2.438,3.052 2.438,3.052 2.135,2.917 true 1.854,1 1.24,0.979 1.24,0.979 1.635,0.927 true 1.625,1.104 2.365,1.115 2.365,1.115 1.865,1.042 true 2.396,1.031 2.583,1.177 0.188,0.146 10 false *d 1.021,0.917 1.198,1.063 0.177,0.146 10 false *c 0.625,2.854 0.781,3.042 0.156,0.188 10 false *a 2.604,3.271 2.771,3.458 0.167,0.188 10 false *a 0.604,3.417 0.76,3.604 0.156,0.188 10 false *b 2.604,2.969 2.771,3.156 0.167,0.188 10 false *b 1.063,4.427 1.229,4.573 0.167,0.146 10 false *f 2.021,4.26 2.188,4.448 0.167,0.188 10 false *e
*a Open
*b Close
*c Advance Side Path
*d Retard Side Path
*e Vinyl Tape
*f Rubber Piece


Release the lock pin.

i.

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

HINT:

There are 4 oil paths in the groove of the camshaft. Plug 2 of the paths with rubber pieces.



ii.

Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path, as shown in the illustration.


iii.
A152656
0.802,0.646 1.094,0.646 1.094,0.646 1.604,1.063 true 2.594,0.667 2.438,0.667 2.438,0.667 1.844,0.969 true 2.646,0.583 2.823,0.74 0.177,0.156 10 *a 0.604,0.573 0.781,0.76 0.177,0.188 10 *b
*a Advance Side Path
*b Retard Side Path


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

CAUTION:

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



iv.
A152659
0.802,0.708 1.073,0.708 1.073,0.708 1.594,1.125 true 2.563,0.594 2.417,0.594 2.417,0.594 1.844,1.042 true 2.594,0.5 2.771,0.656 0.177,0.156 10 *c 0.615,1.188 0.813,1.375 0.198,0.188 10 *a 2.625,1.135 2.802,1.302 0.177,0.167 10 *b 0.615,0.625 0.802,0.823 0.188,0.198 10 *d
*a Decompress
*b Hold Pressure
*c Advance Side Path
*d Retard Side Path


Make sure that the camshaft timing exhaust gear assembly turns in the retard direction when reducing the air pressure applied to the advance side path.

HINT:

The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.



v.

When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path.

NOTICE:

Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.




d.

Check for smooth rotation.

i.

Turn the camshaft timing exhaust gear assembly within its movable range (19 to 21°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the camshaft timing exhaust gear assembly turns smoothly.

NOTICE:

When the air pressure is released from the advance side path and then from the retard side path, the camshaft timing exhaust gear assembly automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.




e.

Check the lock at the most advanced position.

i.

Make sure that the camshaft timing exhaust gear assembly is locked at the most advanced position.



Hide 13506 5.INSPECT CHAIN SUB-ASSEMBLY

a.
A162995
1.583,1.125 1.771,1.271 0.188,0.146 10 false *a 0.823,1.823 0.938,1.99 0.115,0.167 10 false 1 0.99,1.823 1.125,2 0.135,0.177 10 false 2 1.146,1.823 1.271,1.99 0.125,0.167 10 false 3 1.313,1.823 1.448,2.01 0.135,0.188 10 false 4 1.458,1.823 1.583,2 0.125,0.177 10 false 5 0.677,1.823 0.802,2.021 0.125,0.198 10 false 0 2.51,1.833 2.729,2.01 0.219,0.177 10 false 14 2.677,1.833 2.917,2 0.24,0.167 10 false 15
*a Measurement Length


Using a spring scale, pull the chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.


b.

Using a vernier caliper, measure the length of 15 links.

Maximum Chain Elongation:

115.2 mm (4.54 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.


Hide 13507 6.INSPECT NO. 2 CHAIN SUB-ASSEMBLY

a.
A162995
1.583,1.125 1.771,1.271 0.188,0.146 10 false *a 0.823,1.813 0.938,1.979 0.115,0.167 10 false 1 0.99,1.813 1.125,1.99 0.135,0.177 10 false 2 1.146,1.813 1.271,1.979 0.125,0.167 10 false 3 1.313,1.813 1.448,2 0.135,0.188 10 false 4 1.458,1.813 1.583,1.99 0.125,0.177 10 false 5 0.677,1.813 0.802,2.01 0.125,0.198 10 false 0 2.5,1.813 2.719,1.99 0.219,0.177 10 false 14 2.708,1.813 2.948,1.979 0.24,0.167 10 false 15
*a Measurement Length


Using a spring scale, pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.


b.

Using a vernier caliper, measure the length of 15 links.

Maximum Chain Elongation:

102.1 mm (4.02 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.


Hide 13519 7.INSPECT OIL PUMP DRIVE GEAR

a.
A053035

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 (1.90 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.


Hide 15163 8.INSPECT OIL PUMP DRIVE SHAFT GEAR

a.
A053036

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 (1.90 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.


Hide 13050 9.INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

a.
A063864

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):

96.8 mm (3.81 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.


Hide 13070A 10.INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

a.
A150911

Place the chain sub-assembly around the camshaft timing exhaust gear assembly.


b.

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

Minimum Gear Diameter (with Chain):

96.8 mm (3.81 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 exhaust gear assembly.


Hide 13521 11.INSPECT CRANKSHAFT TIMING SPROCKET

a.
A053035

Place the chain sub-assembly around the crankshaft timing sprocket.


b.

Using a vernier caliper, measure the diameter of the crankshaft timing sprocket and chain sub-assembly.

Minimum Gear Diameter (with Chain):

51.1 mm (2.01 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 sprocket.


Hide 13559 12.INSPECT CHAIN TENSIONER SLIPPER

a.
A150912

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.


Hide 13561 13.INSPECT NO. 1 CHAIN VIBRATION DAMPER

a.
A150913

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.


Hide 13562 14.INSPECT NO. 2 CHAIN VIBRATION DAMPER

a.
A150914

Using a vernier caliper, measure the No. 2 chain vibration damper wear.

Maximum Wear:

1.0 mm (0.0394 in.)


If the wear is greater than the maximum, replace the No. 2 chain vibration damper.


Hide 13549 15.INSPECT CHAIN TENSIONER PLATE

a.
A126893

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

Maximum Wear:

1.0 mm (0.0394 in.)


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


Hide 13540 16.INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

a.
A250770
0.553,0.51 0.717,0.663 0.164,0.153 10 *a 0.255,0.882 0.415,1.034 0.159,0.153 10 *b 1.309,1.208 1.476,1.361 0.167,0.153 10 *c
*a Raise
*b Move
*c Lock


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


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.


Hide 13511 17.INSPECT CAMSHAFT

a.
EM01628

Inspect the camshaft for runout.

i.

Place the camshaft on V-blocks.


ii.

Using a dial indicator, measure the runout at the center journal.

Maximum Runout:

0.04 mm (0.00157 in.)


If the runout is greater than the maximum, replace the camshaft.



b.
A036687

Inspect the cam lobes.

i.

Using a micrometer, measure the cam lobe height.

Standard Cam Lobe Height:

42.816 to 42.916 mm (1.6857 to 1.6896 in.)


Minimum Cam Lobe Height:

42.666 mm (1.6798 in.)


If the cam lobe height is less than the minimum, replace the camshaft.



c.
A036688

Inspect the camshaft journals.

i.

Using a micrometer, measure the journal diameter.

Standard Journal Diameter:
Journal Position Specified Condition
No. 1 34.449 to 34.465 mm (1.35626 to 1.35689 in.)
Other 22.949 to 22.965 mm (0.90350 to 0.90413 in.)


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

Click hereEngine / Hybrid System>2ZR-FE ENGINE MECHANICAL>CYLINDER HEAD>INSPECTION



Hide 13512 18.INSPECT NO. 2 CAMSHAFT

a.
EM01628

Inspect the No. 2 camshaft for runout.

i.

Place the No. 2 camshaft on V-blocks.


ii.

Using a dial indicator, measure the runout at the center journal.

Maximum Runout:

0.04 mm (0.00157 in.)


If the runout is greater than the maximum, replace the No. 2 camshaft.



b.
A036687

Inspect the cam lobes.

i.

Using a micrometer, measure the cam lobe height.

Standard Cam Lobe Height:

44.336 to 44.436 mm (1.7455 to 1.7494 in.)


Minimum Cam Lobe Height:

44.186 mm (1.7396 in.)


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



c.
A036688

Inspect the No. 2 camshaft journals.

i.

Using a micrometer, measure the journal diameter.

Standard Journal Diameter:
Journal Position Specified Condition
No. 1 34.449 to 34.465 mm (1.35626 to 1.35689 in.)
Other 22.949 to 22.965 mm (0.90350 to 0.90413 in.)


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

Click hereEngine / Hybrid System>2ZR-FE ENGINE MECHANICAL>CYLINDER HEAD>INSPECTION



Hide 11101A 19.INSPECT CYLINDER HEAD SET BOLT

a.
A310319
1.677,0.646 1.99,0.844 0.313,0.198 10 false *a
*a Measurement Length


Using a vernier caliper, measure the length of the cylinder head set bolt from the seat to the end.

Standard Length:

146.8 to 148.2 mm (5.78 to 5.83 in.)


Maximum Length:

149.2 mm (5.87 in.)


HINT:
·

If the length is greater than the maximum, replace the cylinder head set bolt with a new one. Failure to do so may lead to engine damage.

·

If there is any thread deformation, replace the cylinder head set bolt with a new one.




b.
A311574
2.323,0.469 2.635,0.667 0.313,0.198 10 false *a
*a Measurement Point


Using a vernier caliper, measure the minimum diameter of the threads at the measurement point.

Standard Diameter:

9.77 to 9.96 mm (0.385 to 0.392 in.)


Minimum Diameter:

9.4 mm (0.370 in.)


HINT:
·

If the diameter is less than the minimum, replace the cylinder head set bolt with a new one. Failure to do so may lead to engine damage.

·

If there is any thread deformation, replace the cylinder head set bolt with a new one.




Hide 17141 20.INSPECT EXHAUST MANIFOLD

a.
A158847

Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head sub-assembly.

Maximum Warpage:

0.7 mm (0.0276 in.)


If the warpage is greater than the maximum, replace the exhaust manifold.