Engine Unit Inspection

Check that the bearing is not rough or worn.
If necessary, replace the injection gear.

Using a cylinder gauge, measure the inside diameter of the idle gear.

Standard idle gear inside diameter:

44.000 to 44.025 mm (1.732 to 1.734 in.)

Using a micrometer, measure the diameter of the idle gear shaft.

Standard idle gear shaft diameter:

43.955 to 43.990 mm (1.730 to 1.732 in.)

Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement.

Standard oil clearance:

0.01 to 0.07 mm (0.000394 to 0.00276 in.)

Maximum oil clearance:

0.20 mm (0.00787 in.)

Using a precision straightedge and feeler gauge, measure the warpage of the surface of the intake manifold that contacts the cylinder head.

Maximum warpage:

0.4 mm (0.0157 in.)

Using a precision straightedge and feeler gauge, measure the warpage of the surface of the exhaust manifold that contacts the cylinder head.

Maximum warpage:

0.4 mm (0.0157 in.)

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 more than the maximum, replace the camshaft.
   

Inspect the cam lobe height.

1. Using a micrometer, measure the cam lobe height.
   

   Standard cam lobe height:

   46.83 to 46.93 mm (1.844 to 1.848 in.)
   

   Minimum cam lobe height:

   46.68 mm (1.838 in.)
   

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

Inspect the diameter of the camshaft journal.

1. Using a micrometer, measure the diameter of the camshaft journal for the camshaft bearing.
   

   Standard diameter:

   27.969 to 27.985 mm (1.101 to 1.102 in.)
   

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

Using a dial indicator, measure the backlash.

1. Install the 2 camshafts.
   

2. Using a dial indicator, measure the backlash.
   

   Standard backlash:

   0.035 to 0.089 mm (0.00138 to 0.00350 in.)
   

   Maximum backlash:

   0.189 mm (0.00744 in.)
   

   If the backlash is more than the maximum, replace the 2 camshafts.
   

3. Remove the 2 camshafts.
   

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 more than the maximum, replace the camshaft.
   

Inspect the cam lobe height.

1. Using a micrometer, measure the cam lobe height.
   

   Standard cam lobe height:

   46.87 to 46.97 mm (1.845 to 1.849 in.)
   

   Minimum cam lobe height:

   46.72 mm (1.839 in.)
   

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

Inspect the diameter of the camshaft journal.

1. Using a micrometer, measure the diameter of the camshaft journal for the camshaft bearing.
   

   Standard diameter:

   27.969 to 27.985 mm (1.101 to 1.102 in.)
   

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

Clean the bearing caps and journals.

Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cylinder head as a set.

Place the camshaft on the cylinder head.

Lay a strip of Plastigage across each of the journals.

Install the bearing caps.

NOTICE:

Do not turn the camshaft.

Remove the bearing caps.

Measure the Plastigage at its widest point.

Standard oil clearance:

0.025 to 0.062 mm (0.000984 to 0.00244 in.)

Maximum oil clearance:

0.1 mm (0.00394 in.)

Completely remove the Plastigage.

Remove the camshaft.

Install the camshaft.

Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

Standard thrust clearance:

0.035 to 0.185 mm (0.00138 to 0.0728 in.)

Maximum thrust clearance:

0.25 mm (0.00984 in.)

Remove the camshaft.

Using a vernier caliper, measure the diameter of the most elongated threads in the measurement area.

Standard outside diameter:

11.76 to 11.97 mm (0.463 to 0.471 in.)

Minimum outside diameter:

11.6 mm (0.457 in.)

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 smallest diameter.

Check the oil orifice for damage or clogging.
If necessary, replace the cylinder block oil orifice.

Push the ball of the oil check valve with a wooden stick to check if it is stuck.

Text in Illustration

*1	Ball
	Push

Check the No. 1 oil nozzle for damage or clogging.
If necessary, replace the No. 1 oil nozzle sub-assembly.

Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

Using a soft brush and solvent, thoroughly clean the cylinder block sub-assembly.

Using a precision straightedge and feeler gauge, measure the surface of the cylinder block that contacts the cylinder head for warpage.

Maximum warpage:

0.1 mm (0.00394 in.)

Visually check the cylinders for vertical scratches.
If deep scratches are present, rebore all 4 cylinders. If necessary, replace the cylinder block.

Inspect the cylinder bore diameter.

HINT:

There are 3 standard cylinder bore diameter sizes, marked 1, 2 and 3 accordingly. The mark is stamped on the cylinder block.

1. Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.
   

   Standard Diameter:

   Item	Specified Condition
   STD Mark 1	92.00 to 92.01 mm (3.6220 to 3.6224 in.)
   STD Mark 2	92.01 to 92.02 mm (3.6224 to 3.6228 in.)
   STD Mark 3	92.02 to 92.03 mm (3.6228 to 3.6232 in.)
   O/S 0.50	92.50 to 92.53 mm (3.6417 to 3.6429 in.)

   Maximum Diameter:

   Item	Specified Condition
   STD	92.23 mm (3.6311 in.)
   O/S 0.50	92.73 mm (3.6508 in.)

   Text in Illustration

   *1	Axial Direction
   *2	Thrust Direction
   *3	Center
   	Front

   If the diameter is more than the maximum, rebore all 4 cylinders. If necessary, replace the cylinder block sub-assembly.
   If the wear is less than 0.2 mm (0.00787 in.), using a ridge reamer, grind the top of the cylinder.
   

   Text in Illustration

   *1	Ridge Reamer

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

Using solvent and a brush, thoroughly clean the piston.

NOTICE:

Do not use a wire brush.

Using a micrometer, measure the piston diameter according to the following conditions: 1) measure at a right angle to the piston center line, and 2) measure at the indicated distance from the piston head.

Distance:

65 mm (2.56 in.)

Standard Piston Diameter:

Item	Specified Condition
STD Mark 1	91.92 to 91.93 mm (3.6189 to 3.6193 in.)
STD Mark 2	91.93 to 91.94 mm (3.6193 to 3.6197 in.)
STD Mark 3	91.94 to 91.95 mm (3.3197 to 3.6201 in.)
O/S 0.50	92.42 to 92.45 mm (3.6386 to 3.6398 in.)

Standard Pin Hole Inside Diameter:

Item	Specified Condition
Mark A	34.007 to 34.011 mm (1.3389 to 1.3390 in.)
Mark B	34.011 to 34.015 mm (1.3390 to 1.3392 in.)
Mark C	34.015 to 34.019 mm (1.3392 to 1.3393 in.)

Using a micrometer, measure the piston pin diameter.

Standard Piston Pin Diameter:

Item	Specified Condition
Mark A	33.996 to 34.000 mm (1.3384 to 1.3386 in.)
Mark B	34.000 to 34.004 mm (1.3386 to 1.3387 in.)
Mark C	34.004 to 34.008 mm (1.3387 to 1.3389 in.)

Subtract the piston pin diameter measurement from the piston pin hole inside diameter measurement.

Standard oil clearance:

0.007 to 0.015 mm (0.000276 to 0.000591 in.)

Inspect the piston pin fit.

1. At 80°C (176°F), check that the piston pin can be pushed into the piston pin hole with your thumb.
   If the pin can be installed at a lower temperature, replace the piston with pin sub-assembly.
   

Measure the cylinder bore diameter in the thrust direction.

Subtract the piston diameter measurement from the cylinder bore diameter measurement.

Standard oil clearance:

0.07 to 0.09 mm (0.00276 to 0.00354 in.)

Maximum oil clearance:

0.16 mm (0.00639 in.)

HINT:

When the cylinder block is replaced, use a piston with the same number mark as the cylinder diameter marked on a new cylinder block.

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

Standard Groove Clearance:

Item	Specified Condition
No. 1 piston ring	0.060 to 0.100 mm (0.00236 to 0.00394 in.)
No. 2 piston ring	0.050 to 0.095 mm (0.00197 to 0.00374 in.)
Oil ring	0.030 to 0.075 mm (0.00118 to 0.00295 in.)

Maximum groove clearance:

0.20 mm (0.0787 in.)

Insert the piston ring into the cylinder bore.

Using a piston, push the piston ring a little beyond the bottom of the ring travel, 120 mm (4.72 in.) from the top of the cylinder block.

Using a feeler gauge, measure the end gap.

Standard End Gap:

Item	Specified Condition
No. 1 piston ring	0.27 to 0.39 mm (0.0106 to 0.0154 in.)
No. 2 piston ring	0.47 to 0.62 mm (0.0185 to 0.0244 in.)
Oil ring	0.20 to 0.40 mm (0.00787 to 0.0157 in.)

Maximum End Gap:

Item	Specified Condition
No. 1 piston ring	1.21 mm (0.0476 in.)
No. 2 piston ring	1.44 mm (0.0567 in.)
Oil ring	1.22 mm (0.0480 in.)

Using a caliper gauge, measure the inside diameter of the connecting rod bush.

Standard Bush Inside Diameter:

Item	Specified Condition
Mark A	34.012 to 34.016 mm (1.3390 to 1.3392 in.)
Mark B	34.016 to 34.020 mm (1.3392 to 1.3393 in.)
Mark C	34.020 to 34.024 mm (1.3393 to 1.3395 in.)

Subtract the piston pin diameter measurement from the bush inside diameter measurement.

Standard oil clearance:

0.012 to 0.020 mm (0.000472 to 0.000878 in.)

Maximum oil clearance:

0.03 mm (0.0118 in.)

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

1. Check if the connecting rod is bent.
   

   Maximum bend:

   0.03 mm (0.00118 in.) per 100 mm (3.94 in.)
   

   If the bend is more than the maximum, replace the connecting rod sub-assembly.
   




2. Check if the connecting rod is twisted.
   

   Maximum twist:

   0.15 mm (0.00591 in.) per 100 mm (3.94 in.)
   

   If the twist is more than the maximum, replace the connecting rod sub-assembly.
   

Using a vernier caliper, measure the diameter of the tension portion of the bolt.

Standard diameter:

8.5 to 8.6 mm (0.335 to 0.339 in.)

Minimum diameter:

8.3 mm (0.327 in.)

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 (0.00118 in.)
   

   If the circle runout is more than the maximum, replace the crankshaft.
   

Inspect the main journals and crank pins.

1. Using a micrometer, measure the diameter of each main journal and crank pin.
   

   Standard Main Journal Diameter:

   Item	Specified Condition
   Mark 1	69.994 to 70.000 mm (2.7557 to 2.7559 in.)
   Mark 2	69.988 to 69.994 mm (2.7554 to 2.7557 in.)
   Mark 3	69.982 to 69.988 mm (2.7552 to 2.7554 in.)
   U/S 0.25	69.745 to 69.755 mm (2.7459 to 2.7463 in.)
   U/S 0.50	69.495 to 69.505 mm (2.7360 to 2.7364 in.)

   Standard Crank Pin Diameter:

   Item	Specified Condition
   Mark 1	58.994 to 59.000 mm (2.3226 to 2.3228 in.)
   Mark 2	58.988 to 58.994 mm (2.3224 to 2.3226 in.)
   Mark 3	58.982 to 58.988 mm (2.3221 to 2.3224 in.)

   If the diameter is not as specified, check the connecting rod oil clearance (Toyota Fortuner RM00000147Q021X_01_0084.html) and crankshaft oil clearance (Toyota Fortuner RM00000147Q021X_01_0090.html). If necessary, grind or replace the crankshaft.
   

2. Check each main journal and crank pin for taper and out-of-round as shown in the illustration.
   

   Maximum taper and out-of-round:

   0.02 mm (0.000787 in.)
   

   If the taper and out-of-round is more than the maximum, replace the crankshaft.
   

If necessary, grind and hone the main journals and/or crank pins.

1. Grind and hone the main journals and/or crank pins to the finished undersized diameter (refer to the procedures above).
   

2. Install new main journal and/or crank pin undersized bearings.
   

Using a vernier caliper, measure the diameter of the crankshaft bearing cap set bolt in the measuring area.

Standard diameter:

13.5 to 14.0 mm (0.531 to 0.551 in.)

Minimum diameter:

12.6 mm (0.496 in.)