CO/HC INSPECTION HINT:

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1 ENGINE MECHANICAL (2UZFE) CO/HC CO/HC INSPECTION HINT: EM1 EM0KQ09 This check is used only to determine whether or not the idle CO/ HC complies with regulations. 1. INITIAL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) All pipes and hoses of air induction system connected (d) All accessories switched OFF (e) All vacuum lines properly connected (f) SFI system wiring connectors fully plugged (g) Ignition timing checked correctly (h) Transmission in neutral position (i) Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SE CONDS CO/HC Meter 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement orders are prescribed by the applicable local regulations. A

2 EM2 ENGINE MECHANICAL (2UZFE) CO/HC If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given below. (1) Check the airfuel ratio sensors and heated oxygen sensors operation (see page DI507 and DI512 ). (2) See the table below for possible causes, and then inspect and correct the applicable causes if necessary. CO HC Problems Causes Normal High Rough idle 3. Faulty ignitions: Incorrect timing Fouled, shorted or improperly gapped plugs 4. Incorrect valve clearance 5. Leaky intake and exhaust valves 6. Leaky cylinders Low High Rough idle (fluctuating HC reading) High High Rough idle (Black smoke from exhaust) 1. Vacuum leaks: PCV hose Intake manifold Throttle body Brake booster line 2. Lean mixture causing misfire 1. Restricted air filter 2. Faulty SFI system: Faulty pressure regulator Defective ECT sensor Faulty ECM Faulty injectors Faulty throttle position sensor Faulty MAF meter 3350

3 ENGINE MECHANICAL (2UZFE) COMPRESSION COMPRESSION INSPECTION HINT: EM3 EM0KR11 If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE SPARK PLUGS (See page IG1 ) Compression Gauge A CHECK CYLINDER COMPRESSION PRESSURE (a) Insert a compression gauge into the spark plug hole. (b) Fully open the throttle. (c) While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,373 kpa (14.0 kgf/cm 2, 199 psi) or more Minimum pressure: 1,030 kpa (10.5 kgf/cm 2, 149 psi) Difference between each cylinder: 98 kpa (1.0 kgf/cm 2, 14 psi) or less (e) If the cylinder compression in one or more cylinders is low, pour small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damaged. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 4. REINSTALL SPARK PLUGS (See page IG1 ) 3351

4 EM98 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK CYLINDER BLOCK COMPONENTS EM0E918 Water Bypass Pipe Starter Engine Wire Protector Water Pump ORing Knock Sensor 2 x 5 Gasket Engine Mounting Bracket 30.5 (310, 22) Crankshaft Front Oil Seal 15.5 (160, 11) Oil Pressure Sender Gauge Connector 36 (370, 27) VVT Sensor 2 Connector Oil Pump Engine Coolant Drain Union Clamp Tape ORing Gasket Crankshaft Position Sensor Connector 7.5 (76, 66 in. lbf) Oil Strainer No.1 Oil Pan 7.5 (76, 66 in. lbf) Engine Coolant Drain Union Knock Sensor 1 Engine Wire Engine Wire 7.5 (76, 66 in. lbf) 28 (290, 21) 28 (290, 21) 7.5 (76, 66 in. lbf) 28 (290, 21) x 8 VVT Sensor 1 Engine Wire Cover Engine Mounting Bracket x 4 Oil Pan Baffle Plate 7.5 (76, 66 in. lbf) No.2 Oil Pan Gasket N m (kgf cm, ft lbf) Nonreusable part Precoated part : Specified torque 7.5 (76, 66 in. lbf) x (400, 29) A

5 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK EM99 Oil Ring No.1 Piston Ring No.2 Piston Ring Side Rail Expander Side Rail Snap Ring Connecting Rod Piston Piston Pin Snap Ring Connecting Rod Bushing Connecting Rod Bearing See page EM118 1st 24.5 (250, 18) 2nd Turn 90 Connecting Rod Cap ORing Crankshaft Rear Oil Seal Cylinder Block x (80, 71 in. lbf) Rear Oil Seal Retainer Upper Crankshaft Thrust Washer Upper Main Bearing Crankshaft Lower Main Bearing Lower Crankshaft Thrust Washer Main Bearing Cap N m (kgf cm, ft lbf) : Specified torque Nonreusable part See page EM118 1st 27 (275, 20) 2nd Turn 90 A

6 EM100 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK DISASSEMBLY 1. INSTALL ENGINE TO ENGINE STAND 2. REMOVE TIMING BELT AND PULLEYS (See page EM16 ) 3. REMOVE CYLINDER HEAD (See page EM36 ) EM12206 ORing Pull Wire Clamp A REMOVE WATER BYPASS PIPE (a) Disconnect the wire clamp (for knock sensor 1, 2) from bracket of the water bypass pipe. (b) Remove the bolt. (c) Pull out the water bypass pipe from the water pump. (d) Remove the Oring from the water bypass pipe. 5. REMOVE STARTER (See page ST6 ) 6. REMOVE KNOCK SENSORS (See page SF70 ) 7. REMOVE VVT SENSORS (See page SF79 ) LH Side A DISCONNECT ENGINE WIRE FROM LH SIDE OF CYL INDER BLOCK (a) Remove the 2 bolts and engine wire cover from the LH side of the cylinder block. (b) Remove the 2 bolts, disconnect the brackets on the engine wire from the cylinder block and engine mounting bracket. 9. REMOVE OIL COOLER PIPE BRACKET FOR A/T Remove the bolt and bracket. 10. REMOVE ENGINE MOUNTING BRACKETS Remove the 4 bolts and mounting bracket. Remove the 2 mounting brackets. 11. REMOVE WATER PUMP (See page CO6 ) 12. REMOVE NO.2 OIL PAN (See page LU8 ) 13. REMOVE OIL PAN BAFFLE PLATE 14. REMOVE NO.1 OIL PAN (See page LU8 ) 15. REMOVE OIL STRAINER 16. REMOVE OIL PUMP (See page LU8 ) 17. REMOVE ENGINE COOLANT DRAIN UNIONS Remove the 2 drain unions. 3448

7 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK EM101 pry 18. REMOVE REAR OIL SEAL RETAINER (a) Remove the 7 bolts. (b) Using a screwdriver, remove the oil seal retainer by prying the portion between the oil seal retainer and main bearing cap. (c) Remove the Oring. A05086 A CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back an forth. Standard thrust clearance: to mm ( to in.) Maximum thrust clearance: 0.35 mm ( in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. Connecting rod thickness: to mm ( to in.) 20. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE (a) Check the matchmarks on the connecting rod and see it cap to ensure correct reassembly. (b) Remove the 2 connecting rod cap bolts. A05104 A05105 (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 with the connecting rod cap. (d) Clean the crank pin and bearing. (e) Check the crank pin and bearing for peeling and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. 3449

8 EM102 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK Plastigage (f) Lay a strip of Plastigage across the crank pin. A05102 (g) Install the connecting rod cap with the 2 bolts. (see page EM1 18) NOTICE: Do not turn the crankshaft. (h) Remove the 2 bolts, connecting rod cap and lower bearing. (See procedure (b) and (c) above) A05101 (i) Measure the Plastigage at its widest point. Standard oil clearance: to mm ( to in.) Maximum oil clearance: mm ( in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. A05103 Number Mark No.1 No.2 Number Mark No.4 No.3 Number Mark HINT: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the connecting rod cap and crankshaft, then selecting the bearing with the same number as the total. There are 6 sizes of standard bearings, marked 2, 3, 4, 5, 6 and 7. Number mark Connecting rod cap Crankshaft Use bearing EXAMPLE: Connecting rod cap 3 + Crankshaft 1 = Total number 4 (Use bearing 4 ) A05852 A05087 A05853 A

9 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK EM103 Reference Connecting rod big end inside diameter: Mark to mm ( to in.) Mark to mm ( to in.) Mark to mm ( to in.) Mark 4 Crankshaft crank pin diameter: to mm ( to in.) Mark to mm ( to in.) Mark to mm ( to in.) Mark to mm ( to in.) Standard sized bearing center wall thickness: Mark to mm ( to in.) Mark to mm ( to in.) Mark to mm ( to in.) Mark to mm ( to in.) Mark to mm ( to in.) Ridge Reamer A04852 A Mark to mm ( to in.) (j) Completely remove the Plastigage. 21. REMOVE PISTON AND CONNECTING ROD AS SEMBLIES (a) Using a ridge reamer, remove all the carbon from the top of the cylinder. (b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in correct order. 22. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: to mm ( to in.) Maximum thrust clearance: 0.30 mm ( in.) If the thrust clearance is greater than maximum, replace the thrust washers as a set. Thrust washer thickness: to mm ( to in.) 23. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE (a) Uniformly loosen and remove the 10 main bearing cap bolts in several passes, in the sequence shown. A

10 EM104 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK A05093 (b) Using 2 screwdrivers, pry out the main bearing cap, and remove the 5 main bearing caps, 5 lower bearings and 2 lower thrust washers (No.3 main bearing cap only). NOTICE: Be careful not to damage the cylinder block. HINT: Keep the lower bearing and main bearing cap together. Arrange the main bearing caps and lower thrust washers in correct order. (c) Lift out the crankshaft. HINT: Keep the upper bearings and upper thrust washers together with the cylinder block. (d) Clean each main journal and bearing. (e) Check each main journal and bearing for peelings and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. Plastigage (f) (g) Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. A05097 (h) Install the main bearing caps. (See page EM1 18) NOTICE: Do not turn the crankshaft. (i) Remove the main bearing caps. (See procedure (a) and (b) above) A05095 A05098 (j) Measure the Plastigage at its widest point. Standard clearance: No.1, No to mm ( to in.) Others to mm ( to in.) Maximum clearance: mm ( in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. 3452

11 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK EM105 A05089 A05088 A05090 No.3 No.4 No.5 No.2 No.1 Number Mark No.2 No.1 Number Mark No.3 No.4 Number Mark No.5 A05176 HINT: If using a standard bearing, replace it with one having 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. There are 5 sizes of the standard bearings. For No.1 and No.5 position bearings, use bearings marked 3, 4, 5, 6 and 7. For others position bearings, use bearings marked 1, 2, 3, 4 and 5. No.1, No.5 Cylinder block (A) + Crankshaft (B) Mark 0 to 5 6 to to to to 28 EXAMPLE: Cylinder block 08 + Crankshaft 06 = Total number 14 (Use bearing 5 ) Use bearing Others Cylinder block (A) + Crankshaft (B) Mark 0 to 5 6 to to to to 28 EXAMPLE: Cylinder block 08 + Crankshaft 06 = Total number 14 (Use bearing 3 ) Use bearing Reference Cylinder block main journal bore diameter (A): Mark 00 Mark 01 Mark 02 Mark 03 Mark 04 Mark 05 Mark 06 Mark 07 Mark 08 Mark 09 Mark 10 Mark 11 Mark 12 Mark 13 Mark mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) 3453

12 EM106 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK Mark 15 Mark mm ( in.) mm ( in.) Crankshaft main journal diameter (B): Mark 00 Mark 01 Mark 02 Mark 03 Mark 04 Mark 05 Mark 06 Mark 07 Mark 08 Mark 09 Mark 10 Mark 11 Mark mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) Standard bearing center wall thickness: No.1 and No.5 Mark 3 Mark 4 Mark 5 Mark 6 Mark 7 Others to mm ( in.) to mm ( in.) to mm ( in.) to mm ( in.) to mm ( in.) Mark 1 Mark 2 Mark 3 Mark 4 Mark to mm ( in.) to mm ( in.) to mm ( in.) to mm ( in.) to mm ( in.) (k) Completely remove the Plastigage. 24. REMOVE CRANKSHAFT (a) Lift up the crankshaft. (b) Remove the 5 upper main bearings and 2 upper thrust washers from the cylinder block. HINT: Arrange the main bearing caps, bearings and thrust washers in correct order. 25. CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. A

13 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK EM REMOVE PISTON RINGS (a) Using a piston ring expander, remove the 2 compression rings. (b) Remove the 2 side rails and oil ring by hand. HINT: Arrange the piston rings in correct order only. A DISCONNECT CONNECTING ROD FROM PISTON (a) Using a small screwdriver, pry out the 2 snap rings. A04860 (b) Gradually heat the piston to approx. 60 C (140 F). A04887 (c) Using a plasticfaced hammer and brass bar, lightly tap out the piston pin and pin and remove the connecting rod. HINT: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in correct order. A

14 EM108 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK INSPECTION EM0EB20 1. 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. A INSPECT CYLINDER BLOCK (a) Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head and main bearing cap for warpage. Maximum warpage: 0.07 mm ( in.) If warpage is greater than maximum, replace the cylinder block. Cylinder Block Side Main Bearing Cap Side A04850 A04210 A04212 A05178 (b) Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 8 cylinders and replace all the 8 pistons. (See page EM1 15) If necessary, replace the cylinder block. A

15 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK EM109 Front No.2 No.4 No.6 No.8 (c) Inspect the cylinder bore diameter. HINT: There is 1 size of the standard cylinder bore diameter, marked 2 accordingly. The mark is stamped on the top of the cylinder block. No.1 No.3 No.5 No.7 : Mark 2 A04211 Front 2 11 A 1 2 Thrust Direction Axial Direction 10 mm (0.39 in.) Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: to mm ( to in.) Maximum diameter: STD mm ( in.) B C 10 mm (0.39 in.) O/S mm ( in.) If the diameter is greater than maximum, rebore all the 8 cylinders and replace all the 8 pistons. (See page EM1 15) If necessary, replace the cylinder block. A04262 A04851 A05181 (d) Remove the cylinder ridge. If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder. Ridge Reamer A04852 (e) Using vernier calipers, measure the thread outside diameter of the main bearing cap bolt. Standard diameter: to mm ( to in.) Minimum diameter: mm ( in.) If the diameter is less than minimum, replace the cap bolt mm ( in.) A

16 EM1 10 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK 3. CLEAN PISTON (a) Using a gasket scraper, remove the carbon from the piston top. A04877 (b) Using a groove cleaning tool or broken ring, clean the piston ring grooves. A04878 (c) Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush. A04879 Mark 2 Front Mark mm A INSPECT PISTON AND CONNECTING ROD (a) Inspect the piston oil clearance. HINT: There is 1 size of the standard piston diameter, marked 2 accordingly. The mark is stamped on the piston top. (1) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, mm ( in.) from the piston head. Piston diameter: STD Mark to mm ( to in.) O/S to mm ( to in.) (2) Measure the cylinder bore diameter in the thrust directions (see step 2 above). 3458

17 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK EM1 11 (3) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: to mm ( to in.) Maximum oil clearance: 0.13 mm ( in.) If the oil clearance is greater than maximum, replace all the 8 pistons and rebore all the 8 cylinders. (See page EM1 15) If necessary, replace the cylinder block. Cylinder Block No.2 No.4 No.6 No.8 HINT Use a new cylinder block: Use a piston with the same number mark as the cylinder diameter number marked on the cylinder block. Front No.1 No.3 No.5 No.7 : Mark 2 Mark 2 A23615 (b) Inspect the piston ring groove clearance. Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove. Ring groove clearance: No to mm ( to in.) No to mm ( to in.) If the clearance is not as specified, replace the piston. A04880 (c) Inspect the piston ring end gap. (1) Insert the piston ring into the cylinder bore. (2) Using a piston, push the piston ring a little to the bottom of the ring travel, 105 mm (4.13 in.) from the top of the cylinder block. 105 mm A

18 EM1 12 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK (3) Using a feeler gauge, measure the end gap. Standard end gap: No.1 No.2 Oil (Side rail) Maximum end gap: to mm ( to in.) to mm ( to in.) to mm ( to in.) EM7639 No.1 No.2 Oil (Side rail) 1.10 mm ( in.) 1.30 mm ( in.) 0.75 mm ( in.) If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, rebore all the 8 cylinders (See page EM1 15) or replace the cylinder block. 60 C (d) Inspect the piston pin fit. At 60 C (140 F), you should be able to push the piston pin into the piston pin hole with your thumb. A04048 (e) Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for bend. Maximum bend: 0.05 mm ( in.) per 100 mm (3.94 in.) If bend is greater than maximum, replace the connecting rod assembly. Z14454 (2) Check for twist. Maximum twist: 0.15 mm ( in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connecting rod assembly. Z

19 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK EM1 13 (f) Inspect the piston pin oil clearance. (1) Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: to mm ( to in.) EM6525 EM0227 (2) Using a micrometer, measure the piston pin diameter. Piston pin diameter: to mm ( to in.) (3) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: to mm ( to in.) Maximum oil clearance: 0.05 mm ( in.) If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set. Tension Portion (g) Using vernier calipers, measure the tension portion of the connecting rod bolt. Standard diameter: to mm ( to in.) Minimum diameter: 7.00 mm ( in.) If the diameter is less than the minimum, replace the bolt. A INSPECT CRANKSHAFT (a) Inspect for circle runout. (1) Place the crankshaft on Vblocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.04 mm ( in.) If the circle runout is greater than maximum, replace the crankshaft. A

20 EM1 14 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK (b) Inspect the main journals and crank pins. (1) Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: to mm ( to in.) Crank pin diameter: to mm ( to in.) If the diameter is not as specified, check the oil clearance (See page EM100 ). If necessary, replace the crankshaft. (2) Check each main journal and crank pin for taper and outofround as shown. Maximum taper and outofround: 0.02 mm ( in.) If the taper and outofround is greater than maximum, replace the crankshaft. A05122 A05854 A

21 EM1 18 ENGINE MECHANICAL (2UZFE) A04861 CYLINDER BLOCK REASSEMBLY EM12408 HINT: Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets, Orings and oil seals with new ones. 1. ASSEMBLE PISTON AND CONNECTING ROD (a) Using a screwdriver, install a new snap ring on one side of the piston pin hole. 60 C (b) Gradually heat the piston to about 60 C (140 F). A04876 Front Mark (c) (d) (e) Coat the piston pin with engine oil. Position the piston so that the front mark and to the outside mark on the connecting rod face in the same direction as shown in the illustration. Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb. Outside Mark A23613 (f) Using a screwdriver, install a new snap ring on the other side of the piston pin hole. A04860 No.1 No.2 Code Mark 2R 2. INSTALL PISTON RINGS (a) Install the oil ring expander and 2 side rails by hand. (b) Using a piston ring expander, install the 2 compression rings. Code mark: No.1 No.2 None 2R A

22 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK EM1 19 Lower Side Rail 60 No. 2 Compression Expander 45 (c) Position the piston rings so that the ring ends are as shown. NOTICE: Do not align the ring ends. Front Mark 60 Upper Side Rail 45 No. 1 Compression A INSTALL BEARINGS (a) Align the bearing claw with the groove of the connecting rod or connecting cap. (b) Install the bearings in the connecting rod and connecting rod cap. EM6484 No.1 and No.5 Others Upper Lower 22.5 mm 19.5 mm A INSTALL MAIN BEARINGS HINT: Main bearings are of 19.5 mm (0.768 in.) and 22.5 mm (0.886 in.) in width. Install the 22.5 mm (0.886 in.) bearings in the No.1 and No.5 cylinder block journal positions with the main bearing cap. Install the 19.5 mm (0.768 in.) bearings in the other positions. Upper bearings have an oil groove and oil holes, but lower bearings do not. (a) Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings. A04216 Mark 1, 2, 3, 4, or 5 (b) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings. HINT: A number is marked on each main bearing cap to indicate the installation position. A

23 EM120 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK 5. INSTALL UPPER THRUST WASHERS Install the 2 thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward. 6. PLACE CRANKSHAFT ON CYLINDER BLOCK A PLACE MAIN BEARING CAPS AND LOWER THRUST WASHERS ON CYLINDER BLOCK (a) Install the 2 thrust washers on the No.3 bearing cap with the grooves facing outward. A04217 (b) Install the 5 main bearing caps in their proper locations. 8. INSTALL MAIN BEARING CAP BOLTS HINT: The main bearing cap bolts are tightened in 2 progressive steps (steps (b) and (d)). If any one of the main bearing cap bolts is broken or deformed, replace it. A (a) Apply a light coat of engine oil to the threads and under the main bearing cap bolts. (b) Install and uniformly tighten the 10 main bearing cap bolts in several steps, in the sequence shown. Torque: 27 N m (275 kgf cm, 20 ft lbf) If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt. A Front Painted Mark 90 (c) Mark the front of the main bearing cap bolt with paint. (d) Retighten the main bearing cap bolts by 90 in the numerical order shown. (e) Check that the painted mark is now at a 90 angle to the front. (f) Check that the crankshaft turns smoothly. 9. CHECK CRANKSHAFT THRUST CLEARANCE (See page EM100 ) A

24 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK EM INSTALL PISTON AND CONNECTING ROD AS SEMBLIES Using a piston ring compressor, push correctly the numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. Front Mark Front A PLACE CONNECTING ROD CAP ON CONNECTING ROD (a) Match the numbered connecting rod cap with the connecting rod. (b) Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap. A05106 LH Bank Front Outside Mark (Protrusion) RH Bank Front (c) Check that the outside mark of the connecting rod cap is facing in correct direction. 12. INSTALL CONNECTING ROD CAP BOLTS HINT: The connecting rod cap bolts are tightened in 2 progressive steps (steps (b) and (d)). If any one of the connecting rod cap bolts is broken or deformed, replace it. Outside Mark (Protrusion) A05107 A05108 A

25 EM122 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK (a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. (b) Install and alternately tighten the 2 connecting rod cap bolts in several passes. Torque: 24.5 N m (250 kgf cm, 18 ft lbf) If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts. A Front Painted Mark (c) Mark the front of the connecting cap bolt with paint. (d) Retighten the cap bolts by 90 as shown. (e) Check that the painted mark is now at a 90 angle to the front. (f) Check that the crankshaft turns smoothly. 13. CHECK CONNECTING ROD THRUST CLEARANCE (See page EM100 ) A05099 B A B A Seal Width 3 4 mm A INSTALL REAR OIL SEAL RETAINER (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contacting surfaces of the oil seal retainer and cylinder block. Using a razor blade and gasket scraper, remove all the old packing (FIPG) materials from the gasket surfaces and sealing grooves. Thoroughly clean all components to remove all the loose material. Using a nonresidue solvent, clean both sealing surfaces. (b) Apply seal packing to the oil seal retainer as shown in the illustration. Seal packing: Part No or equivalent Install a nozzle that has been cut to a 3 4 mm ( in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. 3470

26 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK EM123 New ORing (c) (d) Install a new Oring to the cylinder block. Install the oil seal retainer with the 7 bolts. Torque: 8.0 N m (80 kgf cm, 71 in. lbf) A04855 Seal Packing 15. INSTALL ENGINE COOLANT DRAIN UNIONS (a) Apply seal packing to 2 or 3 threads. Seal packing: Part No or equivalent P12477 Front Port A04856 (b) Install the 2 drain unions. Torque: 49 N m (500 kgf cm, 36 ft lbf) HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is facing forward. 16. INSTALL OIL PUMP (See page LU15 ) 17. INSTALL OIL STRAINER (See page LU15 ) 18. INSTALL NO.1 OIL PAN (See page LU15 ) 19. INSTALL OIL PAN BAFFLE PLATE (See page LU15 ) 20. INSTALL NO.2 OIL PAN (See page LU15 ) 21. INSTALL WATER PUMP (See page CO8 ) 22. INSTALL ENGINE MOUNTING BRACKETS Install the mounting bracket with the 4 bolts. Install the 2 mounting brackets. Torque: 36 N m (370 kgf cm, 27 ft lbf) LH Side A INSTALL ENGINE WIRE TO LH SIDE OF CYLINDER BLOCK (a) Install the brackets on the engine wire with the 2 bolts. (b) Install the engine wire cover with the 2 bolts. 24. INSTALL OIL COOLER PIPE BRACKET FOR A/T Install the bracket with the bolt. 25. INSTALL VVT SENSORS (See page SF79 ) 26. INSTALL KNOCK SENSORS (See page SF70 ) 27. INSTALL STARTER (See page ST19 ) 3471

27 EM124 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK New ORing Push Wire Clamp A INSTALL WATER BYPASS PIPE (a) Install a new Oring to the water bypass pipe. (b) Apply soapy water to the Oring. (c) Push in the water bypass pipe end into the pipe hole of the water pump. (d) Install the water bypass pipe with the bolt. Torque: 18 N m (185 kgf cm, 13 ft lbf) (e) Install the wire clamp to the bracket of the water bypass pipe. 29. INSTALL CYLINDER HEADS (See page EM60 ) 30. INSTALL TIMING BELT AND PULLEYS (See page EM23 ) 31. DISCONNECT ENGINE FROM ENGINE STAND 3472

28 ENGINE MECHANICAL (2UZFE) mm A23612 CYLINDER BLOCK REPLACEMENT EM1 15 EM REPLACE OVERSIZED (O/S) PISTONS FOR CYL INDER BORING HINT: Bore all the 8 cylinders to match the oversized piston outside diameter. Replace all the piston rings with ones to match the oversized pistons. (a) Keep 8 new oversized pistons. O/S 0.50 piston diameter: to mm ( to in.) (b) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, mm ( in.) from the piston head. (c) Calculate the size to be rebored for each cylinder as follows: Size to be rebored = P + C H P = Piston diameter C = Piston clearance: to mm ( to in.) H = Allowance for honing: 0.02 mm ( in.) or less (d) Bore and hone the cylinders to calculated dimensions. Maximum honing: 0.02 mm ( in.) NOTICE: Excess honing will destroy the finished roundness. SST 2. REPLACE CONNECTING ROD BUSHINGS (a) Using SST and a press, press out the bushing. SST P20665 Oil Hole (b) (c) Align the oil holes of a new bushing and the connecting rod. Using SST and a press, press in the bushing. SST P

29 EM1 16 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK (d) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (See page EM100 ) between the bushing and piston pin. P20667 (e) Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb. 3. REPLACE CRANKSHAFT FRONT OIL SEAL (See page LU13 ) P REPLACE CRANKSHAFT REAR OIL SEAL HINT: There are 2 methods ((a) and (b)) to replace the oil seal. (a) If the rear oil seal retainer is removed from the cylinder block: (1) Using a screwdriver and hammer, tap out the oil seal. A04868 (2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST (3) Apply MP grease to the oil seal lip. SST A04867 (b) If the rear oil seal retainer is installed to the cylinder block: (1) Using a knife, cut off the oil seal lip. (2) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. Cut Position A

30 ENGINE MECHANICAL (2UZFE) CYLINDER BLOCK EM1 17 SST (3) Apply MP grease to a new oil seal lip. (4) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST A

31 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD EM29 CYLINDER HEAD COMPONENTS EM1WZ02 Suction Hose MAF Meter Wire Vacuum Hose PCV Hose Throttle Body Cover Clip P/S Air Hose Intake Air Connector Radiator Assembly No.2 Fan Shroud Fan And Fluid Coupling Assembly A/T Oil Cooler Hose Fan Pulley 12 (122, 9) 29 (296, 21) Drive Belt A/C Compressor Connector A/C Compressor 49 (500, 36) 29 (296, 21) x 4 Engine Under Cover (2WD) 4WD: Engine Under Cover x 5 N m (kgf cm, ft lbf) : Specified torque 29 (296, 21) A

32 EM30 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD Oil Dipstick and Guide for A/T PS Pump 17(175, 13) ORing RH Front Exhaust Pipe Heated Oxygen Sensor 48 (489, 35) 48 (489, 35) Gasket Gasket Gasket Heated Oxygen Sensor Ring 62 (632, 46) Gasket N m (kgf cm, ft lbf) : Specified torque Nonreusable part 62 (632, 46) A

33 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD EM31 RH No.3 Timing Belt Cover 7.5 (76, 66 in. lbf) 16 (160, 12) No.2 Timing Belt Cover Drive Belt Idler Pulley 39 (400, 29) Cover Plate Camshaft Position Sensor Connector Wire Grommet LH No.3 Timing Belt Cover Engine Wire Oil Cooler Pipe 7.5 (76, 66 in. lbf) N m (kgf cm, ft lbf) : Specified torque A23302 RH Camshaft Timing Pulley LH Camshaft Timing Pulley Timing Belt 8.1 (83, 72 in. lbf) 16 (160, 12) 32 (330, 24) Dust Boot Timing Belt Tensioner Fan Bracket N m (kgf cm, ft lbf) : Specified torque 26 (270, 19) A

34 EM32 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD Heater Hose Engine Wire Protector Engine Wire 18 (185, 13) Throttle Body Cover Bracket 18 (185, 13) Rear Water Bypass Joint 7.5 (76, 66 in. lbf) Throttle Control Connector Gasket Injection Connector Fuel Return Hose ECT Sensor Connector ORing 18 (185, 13) Gasket Front Water Bypass Joint Fuel Inlet Hose Engine Wire VSV Connector for EVAP EVAP Hose 7.5 (76, 66 in. lbf) Wire Bracket Gasket Air Switching Valve No.2 Air Tube No.3 Water Inlet and Inlet Housing Assembly Water Bypass Hose Gasket 16 (163, 12) Gasket Gasket 16 (163, 12) Gasket 10 (102, 7) Air Pump Assembly Air Tube No.3 Ignition Coil Connector RH No.1 Timing Belt Rear Plate 7.5 (76, 66 in. lbf) Heater Hose Gasket 10 (102, 7) Ignition Coil Engine Wire LH No.1 Timing Belt Rear Plate N m (kgf cm, ft lbf) : Specified torque Nonreusable part A

35 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD EM33 Vacuum Hose Fuel Pressure Regulator 7.5 (76, 66 in. lbf) 21 (214, 15) ORing 7.5 (76, 66 in. lbf) VSV for Secondary Air Injection System 18 (184, 13) RH Delivery Pipe VSV for EVAP 7.5 (76, 66 in. lbf) VSV Wire Connector for ACIS Throttle Body Assembly 18 (185, 13) Fuel Return Pipe 7.5 (76, 66 in. lbf) VSV for ACIS PCV Union 39 (400, 29) Gasket 7.5 (76, 66 in. lbf) Ventilation Hose Union 39 (400, 29) 7.5 (76, 66 in. lbf) Fuel Pressure Pulsation Damper * 33 (340, 24) 39 (400, 29) Upper Gasket Lower Gasket Front Fuel Pipe 21 (214, 15) Gasket ORing Grommet Injector Insulator LH Delivery Pipe N m (kgf cm, ft lbf) : Specified torque Nonreusable part * For use with SST A

36 EM34 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD Camshaft Timing Oil Control Valve (Bank 2) Connector RH Cylinder Head Cover Engine Wire Clamp Bracket 6.0 (600, 53 in. lbf) Seal Washer Spark Plug Tube Gasket Camshaft Timing Oil Control Valve (Bank 1) Connector x 9 Camshaft Timing Oil Control Valve (Bank 1) ORing 7.5 (76, 66 in. lbf) LH Cylinder Head Cover ORing Engine Wire Clamp 16 (160, 12) 6.0 (600, 53 in. lbf) x 9 Seal Washer Gasket 7.5 (76, 66 in. lbf) Gasket Camshaft Timing Oil Control Valve (Bank 2) Front Bearing Cap Seal Washer Oil Feed Pipe Front Bearing Cap Camshaft Bearing Cap RH Exhaust Camshaft Camshaft Housing Plug Engine Wire Spark Plug Strainer RH Intake Camshaft (with Timing Tube) Semicircular Plug Ground Strap Ground Wire LH Intake Camshaft (with Timing Tube) Camshaft Housing Plug x 10 LH Exhaust Camshaft See page EM60 1st 40 (408, 30) 2nd Turn 90 3rd Turn 90 Ground Wire Semicircular Plug Strainer RH Cylinder Head Gasket Engine Wire Bracket Airfuel Ratio Sensor (Bank 2 Sensor 1) Connector N m (kgf cm, ft lbf) : Specified torque Nonreusable part LH Cylinder Head and Exhaust Manifold Assembly LH Cylinder Head Gasket Airfuel Ratio Sensor (Bank 1 Sensor 1) Connector A

37 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD EM35 Camshaft Drive Gear Camshaft Timing Tube Intake Camshaft Screw Plug Seal Washer 7.5 (80, 66 in. lbf) Exhaust Camshaft 78 (790, 58) Camshaft Oil Seal Camshaft Driven Main Gear 15 (150, 11) Wave Washer N m (kgf cm, ft lbf) : Specified torque Nonreusable part Camshaft Gear Spring Camshaft Driven Subgear Snap Ring A23372 RH Cylinder Head Gasket RH Exhaust Manifold 44 (450, 32) Valve Lifter Keeper Spring Seat Adjust Shim Spring Retainer Valve Spring Oil Seal Valve Guide Bushing Valve LH Cylinder Head Gasket LH Exhaust Manifold 7.5 (76, 66 in. lbf) Heat Insulator 44 (450, 32) Heat Insulator N m (kgf cm, ft lbf) : Specified torque Nonreusable part 7.5 (76, 66 in. lbf) A

38 SST ENGINE MECHANICAL (2UZFE) A03191 CYLINDER HEAD EM45 EM0L109 DISASSEMBLY 1. REMOVE VALVE LIFTERS AND SHIMS HINT: Arrange the valve lifters and shims in correct order. 2. REMOVE VALVES (a) Using SST, compress the valve spring and remove the 2 keepers. SST ( ) (b) Remove the spring retainer, the valve spring, the valve and the spring seat. HINT: Arrange the valves, valve springs, spring seats and spring retainers incorrect order. (c) Using needlenose pliers, remove the oil seal. A

39 EM46 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD INSPECTION EM1X CLEAN TOP SURFACES OF PISTONS AND CYL INDER BLOCK (a) Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface. A03194 (b) Using a surface contacting gasket scraper, remove all the gasket materials from the cylinder block. (c) Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high pressure compressed air. A REMOVE GASKET MATERIAL Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the surface contacting the cylinder block. EM CLEAN COMBUSTION CHAMBERS Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the surface contacting the cylinder block. EM CLEAN VALVE GUIDE BUSHINGS Using a valve guide bushing brush and solvent, clean all the guide bushings. P

40 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD EM47 5. CLEAN CYLINDER HEAD Using a soft brush and solvent, thoroughly clean the cylinder head. EM INSPECT FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage. Maximum warpage: 0.10 mm ( in.) If warpage is greater than maximum, replace the cylinder head. A INSPECT FOR CRACKS Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. EM6327 Measuring Point 50 mm (1.96 in.) A INSPECT CYLINDER HEAD BOLT Using vernier calipers, measure the thread outside diameter of the cylinder head bolt. Standard outside diameter: to mm ( to in.) Minimum outside diameter: 9.70 mm ( in.) If the diameter is less than minimum, replace the bolt. 3395

41 EM48 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD 9. CLEAN VALVES (a) Using a gasket scraper, chip off any carbon from the valve head. (b) Using a wire brush, thoroughly clean the valve. EM INSPECT VALVE STEMS AND GUIDE BUSHINGS (a) Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: to mm ( to in.) A04091 A04087 A04236 Z00052 (b) (c) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intake Exhaust to mm ( to in.) to mm ( to in.) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake Exhaust Maximum oil clearance: to mm ( to in.) to mm ( to in.) Intake Exhaust 0.08 mm ( in.) 0.10 mm ( in.) If the clearance is greater than maximum, replace the valve and guide bushing. (See page EM56 ) 11. INSPECT AND GRIND VALVES (a) Grind the valve enough to remove pits and carbon. (b) Check that the valve is ground to the correct valve face angle. Valve face angle: Z

42 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD EM49 (c) Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than minimum, replace the valve. Margin Thickness EM0181 (d) Check the valve overall length. Standard overall length: Overall Length EM2534 Intake mm ( in.) Exhaust mm ( in.) Minimum overall length: Intake mm ( in.) Exhaust mm ( in.) If the overall length is less than minimum, replace the valve. (e) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. NOTICE: Do not grind off more than minimum. EM Carbide Cutter 12. INSPECT AND CLEAN VALVE SEATS (a) Using a 45 carbide cutter, resurface the valve seats. Remove only metal enough to clean the seats. EM6330 (b) Check the valve seating position. Apply a light coat of Prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate the valve. Width Z

43 EM50 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD mm Z03988 (c) Check the valve face and seat for the following: If blue appears 360 around the face, the valve is concentric. If not, replace the valve. If blue appears 360 around the valve seat, the guide and face are concentric. If not, resurface the seat. Check that the seat contact is in the middle of the valve face with the following width: 1.0 to 1.4 mm (0.039 to in.) If not, correct the valve seats as follows: If the seating is too high on the valve face, use 30 and 45 cutters to correct the seat If the seating is too low on the valve face, use 60 and 45 cutters to correct the seat mm Z03989 (d) (e) Handlap the valve and valve seat with an abrasive compound. After handlapping, clean the valve and valve seat. EM6331 Deviation 13. INSPECT VALVE SPRINGS (a) Using a steel square, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than maximum, replace the valve spring. EM

44 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD EM51 (b) Using vernier calipers, measure the free length of the valve spring. Free length: 54.1 mm (2.130 in.) If the free length is not as specified, replace the valve spring. EM0801 (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 210 to 226 N (21.4 to 23.0 kgf, 47.2 to 50.7 lbf) at 35.0 mm (1.378 in.) If the installed tension is not as specified, replace the valve spring. EM INSPECT CAMSHAFT FOR RUNOUT (a) Place the camshaft on Vblocks. (b) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm ( in.) If the circle runout is greater than maximum, replace the camshaft. A INSPECT CAM LOBES Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake Exhaust Minimum cam lobe height: to mm ( to in.) to mm ( to in.) EM2011 Intake Exhaust mm ( in.) mm ( in.) If the cam lobe height is less than minimum, replace the camshaft. 3399

45 EM52 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD 16. INSPECT CAMSHAFT JOURNALS Using a micrometer, measure the journal diameter. Journal diameter: to mm ( to in.) If the journal diameter is not as specified, check the oil clearance (see step 20). A INSPECT CAMSHAFT TIMING TUBE (a) Using a micrometer, measure the journal diameter. Journal diameter: to mm ( to in.) If the journal diameter is not as specified, check the oil clearance. A23346 Turn (b) Install the timing tube to the intake camshaft, and check the timing tube turns smoothly. If necessary, replace the timing tube and intake camshaft. A23347 EM INSPECT CAMSHAFT GEAR SPRING Using vernier calipers, measure the free distance between the spring ends. Free distance: 18.2 to 18.8 mm (0.717 to in.) If the free distance is not as specified, replace the gear spring. 19. INSPECT CAMSHAFT BEARINGS Check the bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set. Plastigage 20. INSPECT CAMSHAFT JOURNAL OIL CLEARANCE (a) Install the camshaft timing tube to the intake camshaft (see page EM58 ). (b) Clean the bearing caps and camshaft journals. (c) Place the camshafts on the cylinder head. (d) Lay a strip of Plastigage across each of the camshaft journals. A

46 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD EM53 A (e) Install the bearing caps (see page EM60 ). Torque: 7.5 N m (76 kgf cm, 66 in. lbf) for bolt A 16 N m (160 kgf cm, 12 ft lbf) for others NOTICE: Do not turn the camshaft. (f) Remove the bearing caps. A A04099 (g) Measure the Plastigage at its widest point. Standard oil clearance: Camshaft journal to mm ( to in.) Camshaft timing tube journal to mm ( to in.) Maximum oil clearance: A04084 Camshaft journal Camshaft timing tube journal mm ( in.) mm ( in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (h) Completely remove the Plastigage. (i) Remove the camshafts. (j) Remove the camshaft timing tube from the intake camshaft. 21. INSPECT CAMSHAFT THRUST CLEARANCE (a) Install the camshaft timing tube to the intake camshaft (see page EM58 ). (b) Install the camshaft (see page EM58 ). (c) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: A23348 Intake 0 to mm (0 to in.) Exhaust to mm ( to in.) Maximum thrust clearance: Intake Exhaust 0.12 mm ( in.) 0.10 mm ( in.) If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (d) Remove the camshafts. (e) Remove the camshaft timing tube from the intake camshaft. 3401

47 EM54 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD A INSPECT CAMSHAFT GEAR BACKLASH (a) Install the drive gear to the camshaft timing tube (See page EM58 ). (b) Install the camshaft timing tube to the intake camshaft (See page EM58 ). (c) Install the camshafts without installing the exhaust camshaft subgear and front bearing cap (See page EM58 ). (d) Using a dial indicator, measure the backlash. Standard backlash: to mm ( to in.) Maximum backlash: 0.30 mm ( in.) If the backlash is greater than the maximum, replace the intake camshaft drive gear and exhaust camshaft. (e) Remove the camshafts. (f) Remove the camshaft timing tube from the intake camshaft. (g) Remove the drive gear from the camshaft timing tube. 23. INSPECT VALVE LIFTERS AND LIFTER BORES (a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: to mm ( to in.) A to 12.7 mm A03201 (b) Using a micrometer, measure the lifter diameter at the valve lifter center line, 12.3 to 12.7 mm (0.484 to in.) from the valve lifter head. Lifter diameter: to mm ( to in.) (c) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: to mm ( to in.) Maximum oil clearance: 0.07 mm ( in.) If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head. 3402

48 ENGINE MECHANICAL (2UZFE) CYLINDER HEAD EM INSPECT EXHAUST MANIFOLDS Using a precision straight edge and feeler gauge, measure the warapage of the surface that is in contact with the cylinder head. Maximum warpage: 0.10 mm ( in.) If warpage is greater than maximum, replace the manifold. A

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