Engine Unit

3MZ-FE ENGINE MECHANICAL: ENGINE UNIT:

INSPECTION

1. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY





(a) Clamp the camshaft in a vise on the hexagonal lobe.
(b) Check that the VVT-i does not turn.





(c) Cover all the oil ports with vinyl tape except the port on the advanced angle side (nearest to the convex portion) shown in the illustration.
(d) Using an air gun, apply about 100 kPa (1 kgf/cm 2, 14 psi) of air pressure to the port on the advanced angle side.

NOTE: Some oil spraying will occur. Contain the spray with a shop rag.

HINT: This operation releases the lock pin for the extreme retarded angle lock.

(e) Under the condition above, check that the VVT-i can be turned by hand to the advanced angle side, the direction of the white arrow in the illustration.
Standard:
Can be turned

HINT: The VVT-i will turn to the advanced angle side without applying force by hand depending on the force of the air pressure applied. Also, if applying pressure to the oil path is difficult as a result of air leakage from the port, the lock-pin may be difficult to release.

(f) Check that the VVT-i moves freely within a 30° range. Avoid moving the VVT-i unit to the extreme retarded angle position as the lock-pin will re-engage.
Standard:
Smooth movable range is about 30°
(g) Turn VVT-i by hand and lock it at the extreme retarded angle position.
2. INSPECT TIMING BELT

NOTICE:
- Do not bend, twist or turn the timing belt inside out.
- Do not allow the timing belt to come into contact with oil, water or steam.
- Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley.

Check the belt for any defects, as shown in the illustrations. Also, check these points below.





(a) If there is premature parting:

- Check for proper installation.
- Check the timing cover gasket for damage and proper installation.

(b) If the belt teeth are cracked or damaged, check to see if either camshaft is locked.
(c) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock and water pump.
(d) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.
(e) If there is noticeable wear on the belt teeth:

- Check the timing cover for damage.
- Check that the gasket has been installed correctly.
- Check for foreign object on the pulley teeth.
If there is any doubt about the belt condition, replace the timing belt.

3. INSPECT CAMSHAFT





(a) Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the runout at the center journal.
Maximum circle runout:
0.06 mm (0.0024 in.)
If the runout is greater than the maximum, replace the camshaft.





(b) Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe height.
Specified 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.
Journal diameter:
26.959 to 26.975 mm (1.0614 to 1.0620 in.)
If the journal diameter is not as specified, check the oil clearance.
4. INSPECT CYLINDER HEAD SET BOLT





(a) Using a vernier caliper, measure the tension portion diameter of the bolt.
Specified outside diameter:
8.75 to 9.05 mm (0.3445 to 0.3563 in.)
If the diameter is less than the minimum, replace the bolt.
5. INSPECT CRANKSHAFT THRUST CLEARANCE





(a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Specified thrust clearance:
0.04 to 0.30 mm (0.0016 to 0.0118 in.)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Check the crankshaft for wear, repair or replace if necessary.
Thrust washer thickness:
1.93 to 1.98 mm (0.0760 to 0.0780 in.).
6. INSPECT CRANKSHAFT OIL CLEARANCE





(a) Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the sequence shown in the illustration (Procedure "A").





(b) Uniformly loosen and remove the 16 main bearing cap bolts the sequence shown in the illustration (Procedure "B").
(c) Remove the 4 main bearing caps and 4 lower bearings. Also remove the 2 lower thrust washers, located under the No. 2 main bearing cap (Procedure "C").





- Keep the lower bearing and main bearing cap together.





- Arrange the main bearing caps and lower thrust washers in correct order.

NOTE: Using a screwdriver, push up on the cap little by little, alternating from the right to left side until the cap is free. Take care not to damage the contact surfaces of the cap and cylinder block.





(d) Lift out the crankshaft.

HINT: Keep the upper bearings together with the cylinder block.

(e) Clean each main journal and bearing.
(f) Check each main journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.





(g) Place the crankshaft on the cylinder block.
(h) Lay a strip of Plastigage across each journal.





(i) Install the 4 main bearing caps.

NOTE: Do not turn the crankshaft.

(j) Remove the main bearing caps (See procedure "A" to "C" ).





(k) Measure the Plastigage at its widest point.
Specified oil clearance:





If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.





(l) Check number mark.

HINT: If using a bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. The No. 1 and No. 4 journal bearings have 5 standard bearing sizes, marked 3, 4, 5, 6 and 7 accordingly. The No. 2 and No. 3 journal bearings have 5 standard bearing sizes, marked 1, 2, 3, 4 and 5 accordingly.

No. 1 and No. 4 journal bearings:





HINT: EXAMPLE:

Cylinder block imprinted number mark is 06

Crankshaft imprinted number mark is 08

6 + 8 = 14

Select the bearing marked "5"





No. 2 and No. 3 journal bearings:





HINT: EXAMPLE:

Cylinder block imprinted number mark is 06

Crankshaft imprinted number mark is 08

6 + 8 = 14

Select the bearing marked "3"





(m) Completely remove the Plastigage.
7. INSPECT CYLINDER BLOCK FOR FLATNESS





(a) Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
Maximum warpage:
0.05 mm (0.0020 in.)
If the warpage is greater than the maximum, replace the cylinder block.
8. INSPECT CYLINDER BORE





(a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
Specified diameter:
92.000 to 92.132 mm (3.6220 to 3.6272 in.)
If the diameter is greater than the maximum, replace the cylinder block.
9. INSPECT W/PIN PISTON SUB-ASSEMBLY





(a) Using a micrometer, measure the diameter of the piston. When you measure the diameter, attach the micrometer to a location 13.0 mm (0.512 in.) above the pistons bottom and perpendicular to the piston pin hole.
Piston diameter:
91.953 to 91.967 mm (3.6202 to 3.6207 in.)
10. INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Specified oil clearance:
0.033 to 0.130 mm (0.0013 to 0.0051 in.)
If the oil clearance is greater than the maximum, replace all the 6 pistons. If necessary, replace the cylinder block.
11. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) Using a rod aligner and feeler gauge, check the connecting rod alignment.





(1) Check for misalignment.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If misalignment is greater than the maximum, replace the connecting rod assembly.





(2) Check for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum, replace the connecting rod assembly.
12. INSPECT PISTON PIN OIL CLEARANCE





(a) 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.)





(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) Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Specified oil clearance:
0.005 to 0.050 mm (0.0002 to 0.0020 in.)
If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the piston and the piston pin together.
13. INSPECT RING GROOVE CLEARANCE





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





If the clearance is not as specified, replace the piston.
14. INSPECT PISTON RING END GAP





(a) 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.





(b) Using a feeler gauge, measure the end gap.
Specified 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, replace the cylinder block.
15. INSPECT CONNECTING ROD BOLT





(a) Using a vernier caliper, measure the tension portion diameter of the bolt.
Specified diameter:
7.0 to 7.3 mm (0.276 to 0.287 in.)
If the diameter is less than the minimum, replace the bolt.
16. INSPECT CRANKSHAFT BEARING CAP SET BOLT





(a) Using a vernier caliper, measure the tension portion diameter of the bolt.
Specified diameter:
7.2 to 7.6 mm (0.283 to 0.299 in.)
If the diameter is less than the minimum, replace the bolt.
17. INSPECT CRANKSHAFT





(a) Using a dial indicator and V-blocks, measure the runout as shown in the illustration.
Maximum circle runout:
0.06 mm (0.0024 in.)
If the circle runout is greater than the maximum, replace the crankshaft.





(b) Using a micrometer, measure the diameter of each main journal.
Diameter:
60.988 to 61.000 mm (2.4011 to 2.4016 in.)
If the diameter is not as specified, check the oil clearance (see step 7).
If necessary, replace the crankshaft.
(c) Check each main journal 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.





(d) Using a micrometer, measure the diameter of each crank pin.
Diameter:
52.992 to 53.000 mm (2.0863 to 2.0866 in.)
If the diameter is not as specified, check the oil clearance (see step 7).
(e) Check each 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.