Maintenance of the mechanical part of the engine Data for servicing the mechanical part of the engine are presented in Table 2.31. See the table for service intervals. 2.32. Table 2.31. Data for servicing the mechanical part of the 1MZ-FE engine Table 2.32....
Valve clearances — getting started Note. Checking and adjusting the thermal clearances in the valves is carried out only on a cold engine. Using a 5mm socket wrench, unscrew the two nuts and remove the engine cover. Pic. 2.221. Removing the upper part of...
Removing the cylinder head cover Pic. 2.222. Removing the wiring protection Disconnect the two crankcase ventilation hoses from the cylinder head cover. Disconnect the two harness guard clips from the #2 timing belt cover bolts. Remove the four nuts,...
Installing the piston of the 1st cylinder at TDC of the compression stroke Pic. 2.223. Alignment of the risks of the crankshaft pulley with the marking «0» on the timing belt cover Rotating the crankshaft pulley, align the risk on the pulley with the installation marking «0» on the timing belt...
Checking thermal clearances in valves Pic. 2.224. Checking thermal clearances in valves Check up thermal backlashes in the valves specified in drawing 2.224. Using a feeler gauge, measure the clearance between the cam and the valve lifter. Write down the...
Valve clearance adjustment If necessary, adjust the thermal clearance in the valves. To do this, remove the adjusting washer. Pic. 2.227. The correct location of the valve lifter Rotate the camshaft so that the top of the cam is pointing up....
Removing the timing belt Loosen the generator mounting bolt, unscrew the nut and remove the generator bracket No. 2. Pic. 2.233. Removing the timing pulley: 1 - special tools Holding the crankshaft pulley with special tools 09213-54015 and...
Checking the timing belt Pic. 2.238. Checking the timing belt Pic. 2.239. The sequence of installing the timing belt on the elements of the mechanism Do not bend or twist the timing belt. Do not allow the toothed belt to come into contact with...
Timing belt installation Set the piston of the 1st cylinder to the TDC of the compression stroke. Pic. 2.235. Alignment of the alignment marks on the crankshaft sprocket and the oil pump housing Temporarily install the crankshaft pulley bolt...
Removing the cylinder head — preparatory operations Drain the coolant from the cylinder block and radiator. Pic. 2.242. Removing the engine protective cover: 1 - end key; 2 - clips Using a 5mm socket wrench, unscrew the two nuts and remove the top protective cover (pic....
Removing the intake and exhaust valve shafts Since the end play of the camshaft is very small, to prevent jamming and/or damage to the camshaft when removing it, it is necessary to keep the shaft in a horizontal position, for this it is necessary to follow the...
Disassembly of the exhaust camshafts Pic. 2.257. Installing the camshaft in a vise Establish a camshaft for a six-sided site in a vice, as it is shown in drawing 2.257. Note. Be careful not to damage the camshaft Pic. 2.258. Turning the auxiliary gear: 1 -...
Removing cylinder heads Pic. 2.260. The order of loosening the bolts with an internal hexagon on each cylinder head Using an 8mm wrench, remove the hexagon socket head bolts on each cylinder head (pic. 2.260). Pic. 2.261. The order of...
Removing valves Before removing the valves, remove the tappets and shims. Store tappets and shims in the order in which they were installed. Pic. 2.262. Removing crackers: 1 - special tool Using the special tool, compress the valve...
Cleaning the cylinder head Clean the bottoms of the pistons and the surface of the cylinder block mating with the cylinder head. Turning the crankshaft, sequentially set the pistons to TDC. With a scraper, clean the surfaces of the piston bottoms...
Checking the cylinder head for warping Pic. 2.263. Checking the cylinder head With a precision ruler and a flat feeler gauge, as shown in Figure 2.263, check the warping of the working surfaces of the cylinder head mating with the surface of the cylinder...
Valve and Guide Replacement Pic. 2.267. Heating the cylinder head in a water bath Gradually heat the cylinder head in a water bath to a temperature of 80-100°C (pic. 2.267). Pic. 2.268. Pressing out the guide bushing: 1 - drift Using a drift and...
Checking and lapping valves Pic. 2.273. Valve plate thickness Grind the valves until traces of soot and scratches are eliminated. Ensure that the lapped bevel of the valve forms an angle of 44.5°with respect to a plane perpendicular to the axis of...
Checking the valve spring Pic. 2.277. Valve spring check Using a metal square (90°), check the non-perpendicularity of the valve spring, as shown in Figure 2.277. The maximum allowable non-perpendicularity is 2.0 mm. Pic. 2.278. Valve Spring...
Valve lifter check Pic. 2.280. Valve lifter diameter measurement Measure the diameter of the valve lifter with a micrometer (pic. 2.280). The pusher diameter is 30.968–30.976 mm. Calculate the oil clearance. Subtract the tappet diameter...
Checking the end play of the camshaft Pic. 2.281. Checking the end play of the camshaft Install the camshaft in the bed of the cylinder head. Using an indicator, measure the axial clearance while moving the camshafts back and forth (pic. 2.281). Axial...
Measuring the backlash in the gearing of the camshafts Pic. 2.282. Measuring the backlash in the gearing of the camshafts Install both camshafts in the head of the block without installing the exhaust camshaft auxiliary gear. Use a dial indicator to measure the backlash in...
Checking the bore for pushers in the block head housing Pic. 2.283. Checking the bore for pushers in the block head housing Using an indicator-bore gauge, measure the diameters of the bores for the pushers in the cylinder head (pic. 2.283). The diameter of the bore for the...
Checking the oil clearance in the camshaft bearings Pic. 2.284. Placing a plastic gauge on each camshaft journal: 1 - plastic gauge Clean the working surfaces of the camshaft journals and bearing caps. Lay the camshafts in the bed of the cylinder head. Place a piece of...
Cylinder head assembly Note. Before assembly, clean all parts to be assembled. Apply fresh engine oil to all friction surfaces. Replace all gaskets and seals. Pic. 2.286. Pressing in a new spark plug tube Install new spark plug tubes. Apply...
Installing the cylinder head Install the cylinder heads to the cylinder block, after installing new head gaskets on it. Install the cylinder head bolts. Note. The cylinder head bolts are tightened in two stages. If any cylinder head bolt is broken...
Assembly of exhaust camshafts Clamp the camshaft at the hex section in a vise. Install the following parts: 1 - spring ring of the camshaft gear; 2 - auxiliary gear of the camshaft drive; 3 - spring washer. Note. Align the drive pins on the gears...
Installation of exhaust camshafts Install the camshafts. Note. When installing camshafts, keep in mind that the axial clearance is very small, so the shafts must be laid in the bearing bed strictly horizontally, without distortion, in order to avoid...
Installation of a camshaft of inlet valves of a back head of the block Pic. 2.297. Combination of labels of gear wheels of a drive of a camshaft Apply a layer of engine oil to the end thrust surfaces of the camshaft. Engage the gears of the camshaft drive of the exhaust and intake valves,...
Installation of a camshaft of final valves of a back head of the block Pic. 2.300. Combination of labels of gear wheels of a drive of a camshaft Apply a layer of engine oil to the end thrust surfaces of the camshaft. Install the exhaust camshaft 90°from the position where the timing marks...
Installation of a camshaft of inlet valves of a forward head of the block Pic. 2.304. Combination of labels of gear wheels of a drive of a camshaft Apply a layer of engine oil to the end thrust surfaces of the camshaft. Engage the gears of the camshaft drive of the exhaust and intake valves,...
Installing the cylinder head cover Remove the remnants of the old gaskets. Apply sealant to cylinder heads. Install the gaskets on the cylinder head covers. Establish covers of heads of the block of cylinders and wrap on eight bolts of fastening. Tighten...
Installing the rest of the cylinder head components Install a new gasket and exhaust manifold and tighten the six mounting nuts evenly in several passes to 49 Nm. Install the power steering pump bracket and torque the mounting bolts to 43 Nm. Install the mounting plate...
Disassembly of the cylinder block — preliminary operations Install the engine on a stand for disassembly. Remove the timing belt and its pulleys. Remove the cylinder heads. Remove the alternator, alternator belt adjuster bracket and bracket assembly. Remove the emergency oil...
Checking the end play of the connecting rod bearing Pic. 2.318. Checking the end play of the connecting rod bearing Using a dial indicator, moving the connecting rod back and forth along the connecting rod journal of the crankshaft, check the axial play of the connecting...
Checking the radial play of the connecting rod bearing Pic. 2.319. Unscrewing the connecting rod bottom cap bolts Check the alignment of the marks on the connecting rod and the connecting rod cap to ensure proper assembly in the future. If there are no marks, apply them to...
Removing the piston and connecting rod assembly Pic. 2.323. Removing carbon deposits from the top of the cylinder using a reamer Use a reamer to remove carbon deposits from the top of the cylinder, as shown in Figure 2.323. Remove the piston assembly with connecting...
Measuring the end play of the crankshaft Pic. 2.324. Measurement of crankshaft end play Using a dial indicator, measure the axial play of the crankshaft by moving the latter «back forward» with a screwdriver (pic. 2.324). Standard axial play - 0.04–0.24 mm....
Checking oil radial clearances Remove the main bearing caps and check the radial oil clearances. Pic. 2.325. Extraction of coupling bolts of fastening of covers of radical bearings Evenly loosen and unscrew the eight coupling bolts of the main...
Checking the block of cylinders Remove the remnants of gaskets from the working surfaces of the block with a scraper, scraper, metal brush. Solvent and soft brush finally clean the cylinder block. Pic. 2.329. Checking the cylinder block for warpage...
Cylinder diameter measurement Pic. 2.330. Cylinder diameter measurement Indicator-caliper measure the diameter of the cylinder at three levels A, B and C in the transverse 1 and longitudinal 2 directions, as shown in Figure 2.330. The standard...
Disassembly of the connecting rod and piston group Check the fit of the connecting rod-piston group by trying to move the piston «back and forth» on the piston pin in a direction perpendicular to the axis of the piston pin. If there is noticeable play, replace the...
Checking clearance between piston and cylinder Pic. 2.333. Measuring the skirt diameter Using a micrometer, measure the piston skirt diameter at a distance of 23.2 mm (pic. 2.333). The nominal diameter of the piston is 87.406–87.416 mm. Measure the cylinder...
Checking the concentricity of the connecting rod heads Pic. 2.334. Checking bending and twisting of the connecting rod Using a special tool and a flat feeler gauge, check the bending of the connecting rod. In a similar way, check the twisting of the connecting rod, as shown...
Piston pin oil clearance check Pic. 2.335. Piston pin oil clearance check Using a inside gauge, measure the inside diameter of the connecting rod bushing (pic. 2.335). The inner diameter of the sleeve is 22.005–22.014 mm.
Piston pin measurement Pic. 2.336. Piston pin measurement Using a micrometer, measure the diameter of the piston pin (pic. 2.336). Piston pin diameter - 21.997–22.006 mm. Subtract the piston pin diameter from the bushing inner diameter....
Checking the End Gap of the Compression Ring Pic. 2.341. Checking the End Gap of the Compression Ring Check end clearance «compression ring - piston groove», measuring it with a flat probe, as shown in Figure 2.341. Rated Clearance: compression ring No. 1 -...
Checking the clearance in the piston ring lock Pic. 2.342. Checking the clearance in the piston ring lock To check the clearance in the piston ring lock, insert the piston ring into the cylinder. Piston push the ring to a distance of 105 mm from the surface of the...
Checking the runout of the crankshaft Pic. 2.344. Measurement of crankshaft runout Place the crankshaft on the prisms. Using a dial indicator, check the runout of the crankshaft on the central main journal (pic. 2.344). The maximum runout is 0.06 mm. If the...
Checking the connecting rod and main journals Pic. 2.345. Measurement planes for connecting rod and main journals Micrometer measure the diameter of each connecting rod and main journal in two mutually perpendicular planes, as shown in Figure 2.345. Main journal...
Selection of studs and plugs Pic. 2.356. Stud selection table for cylinder block Pick up hairpins and plugs for the block of cylinders, being guided by illustrations 2.356 and 2.357. Pic. 2.357. Cylinder block plug selection table
Assembling the connecting rod and piston group Pic. 2.358. Installing a new retaining ring Using a screwdriver, install a new retaining ring on one side into the groove of the piston cylinder (pic. 2.358). Pic. 2.359. Heating of pistons in a special box Gradually...
Installation of piston rings Pic. 2.361. Scheme of installation of compression rings Install the expander and two oil scraper ring expanders. Use a piston ring expander to install two compression rings; moreover, the marks of the rings should be...
Installing connecting rod bearing shells Pic. 2.363. Installing a bushing in the lower head of the connecting rod Align the lug of the bushing with the recess in the lower head of the connecting rod and with its cap. Insert the bushings into the bottom end of...
Cylinder block assembly Pic. 2.364. Main bearing shells Install the main bearing shells. The main bearing shells vary in width, in addition, the upper main bearing shells have an oil channel and oil holes (pic. 2.364). Pic. 2.365. Number...
Installing the coolant drain plug Pic. 2.370. Places for applying sealant to the plug of the cooling system Remove the remnants of the old gasket, flush the plug of the cooling systems, clean the surfaces of the plug and block with a volatile solvent,...
Oil pump installation Pic. 2.373. Places for applying sealant to the contact surface of the oil pump Remove any remaining sealing material from the contact surfaces of the oil pump. Using solvent, clean the contact and seal surfaces. Apply a...
Oil pan installation Install the oil separator on top of the oil pan. Using solvent, clean the contact and seal surfaces. Note. Do not use a solvent that will attack painted surfaces. Pic. 2.375. Places for applying sealant to the contact...
Installing the lower part of the oil pan Pic. 2.376. Places for applying sealant to the contact surface of the lower part of the oil pan Remove any remaining sealing material and use a solvent to clean the contact and seal surfaces. Apply sealant to the...
Installing the thermostat housing Pic. 2.377. Places for applying sealant to the contact surface of the thermostat housing Remove the remnants of the old gasket, flush the housing, clean the surfaces of the housing and block with a volatile solvent and...