Part 1

2GR-FSE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION

INSPECTION

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

(a) Turn the roller by hand to check that it turns smoothly.
HINT:
If the roller does not turn smoothly, replace the valve rocker arm sub-assembly.

2. INSPECT VALVE LASH ADJUSTER ASSEMBLY
NOTICE:
- Keep the lash adjuster free of dirt and foreign objects.
- Only use clean engine oil.

(a) Place the lash adjuster into a container filled with engine oil.

(b) Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.
SST: 09276-75010
(c) Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
(d) Check the movement of the plunger and bleed the air.
OK:
Plunger moves up and down.
NOTE:
When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

(e) After bleeding the air, 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 lash adjuster.
3. INSPECT CAMSHAFT
(a) Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.

(2) Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout:
0.04 mm (0.0016 in.)
If the circle runout is greater than the maximum, replace the camshaft.
HINT:
Check the oil clearance after replacing the camshaft.

(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:

Maximum cam lobe height:

If the journal diameter is not as specified, check the oil clearance.
4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Clamp the camshaft in a vise.
NOTE:
Be careful not to damage the camshaft in the vise.

(b) Put the camshaft timing gear and camshaft together by aligning the key groove and straight pin.
(c) Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.
NOTE:
Be sure not to turn the camshaft timing gear in the retard direction (the right angle).

(d) Check that there is no clearance between the gear's flange and the camshaft.

(e) Tighten the flange bolt with the camshaft timing gear fixed.
Torque: 100 Nm (1,020 kgf-cm, 74 ft-lbf)
(f) Check the lock of the camshaft timing gear.
(1) Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked.
NOTE:
Be careful not to damage the camshaft.

(g) Release the lock pin.

(1) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
HINT:
2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece.
(2) Break through the tape of the advance side path and the retard side path on the opposite side to the hole of the advance side path, as shown in the illustration.

(3) Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the two broken paths.
CAUTION:
Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.

(4) Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path.
HINT:
This operation releases the lock pin for the most retarded position.
(5) When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path, in that order.
NOTE:
Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

(h) Check for smooth rotation.
(1) Turn the camshaft timing gear within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.
NOTE:
Do not use air pressure to perform the smooth operation check.

(i) Check the lock in the most retarded position.
(1) Confirm that the camshaft timing gear is locked at the most retarded position.

(j) Remove the flange bolt and camshaft timing gear.
- Do not remove the other 3 bolts.
- If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

5. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
(a) Clamp the camshaft in a vise.
NOTE:
Be careful not to damage the camshaft in the vise.

(b) Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and straight pin.
(c) Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.
NOTE:
Be sure not to turn the camshaft timing exhaust gear in the retard direction (the right angle).

(d) Check that there is no clearance between the gear's flange and the camshaft.

(e) Tighten the flange bolt with the camshaft timing exhaust gear fixed.
Torque: 100 Nm (1,020 kgf-cm, 74 ft-lbf)
(f) Check the camshaft timing exhaust gear lock.
(1) Make sure that the camshaft timing exhaust gear is locked.
(g) Release the lock pin.

(1) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
HINT:
4 oil paths are provided in the groove. Plug 2 paths with rubber pieces.
(2) 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.

(3) Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the 2 broken 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 splashing.

(4) Make sure that the camshaft timing exhaust gear 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 turns in the retard direction.
(5) When the camshaft timing exhaust gear 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.
NOTE:
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 may abruptly shift in the advance direction and break the lock pin or other parts.

(h) Check for smooth rotation.
(1) Turn the camshaft timing exhaust gear within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.
NOTE:
When the air pressure is released from the advance side path and then from the retard side path, the gear 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.

(i) Check the lock at the most advanced position.
(1) Make sure that the camshaft timing exhaust gear is locked at the most advanced position.

(j) Remove the flange bolt and camshaft timing exhaust gear.
- Be sure not to remove the other 4 bolts.
- If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

6. INSPECT CYLINDER HEAD SET BOLT

(a) Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point.
Standard outside diameter:
10.85 to 11.00 mm (0.4272 to 0.4331 in.)
Minimum outside diameter:
10.70 mm (0.4213 in.)
Measuring Point:
100 mm (3.94 in.)
HINT:
If a visual check reveals no excessively thin areas, check the center of the bolt and find the area that has the lowest diameter.
If the diameter is less than the minimum, replace the cylinder head bolt.
7. INSPECT CHAIN SUB-ASSEMBLY

(a) Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.
(b) Using vernier calipers, measure the length of 15 links.
Maximum chain elongation:
136.9 mm (5.390 in.)
NOTE:
Perform the measurement at 3 random places. Inspect using the average of the measurements.
If the elongation is greater than the maximum, replace the chain.
8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY

(a) Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.
(b) Using vernier calipers, measure the length of 15 links.
Maximum chain elongation:
137.6 mm (5.417 in.)
NOTE:
Perform the measurement at 3 random places. Inspect using the average of the measurements.
If the elongation is greater than the maximum, replace the chain.
9. INSPECT CRANKSHAFT TIMING SPROCKET
(a) Wrap the chain around the sprocket.

(b) Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain):
61.4 mm (2.417 in.)
HINT:
The vernier calipers must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the chain and sprocket.
10. INSPECT IDLE SPROCKET ASSEMBLY
(a) Wrap the chain around the sprocket.

(a) Using a micrometer, measure the idle gear shaft diameter.
Idle gear shaft diameter:
22.987 to 23.000 mm (0.9050 to 0.9055 in.)

(b) Using a caliper gauge, measure the inside diameter of the idle gear.
Idle gear inside diameter:
23.020 to 23.030 mm (0.9063 to 0.9067 in.)
(c) Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement.
Standard oil clearance:
0.020 to 0.043 mm (0.0008 to 0.0017 in.)
Maximum oil clearance:
0.093 mm (0.0037 in.)
If the thrust oil clearance is greater than the maximum, replace the idle gear shaft and idle gear.
12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly.
If necessary, replace the chain tensioner assembly.
13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Check that the plunger moves smoothly.
(b) Measure the worn depth of the chain tensioner.
Maximum depth:
0.9 mm (0.035 in.)
If the depth is greater than the maximum, replace the chain tensioner assembly.
14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Measure the worn depth of the chain tensioner slipper.
Maximum depth:
1.0 mm (0.039 in.)
If the depth is greater than the maximum, replace the chain tensioner slipper.
16. INSPECT NO. 1 CHAIN VIBRATION DAMPER

(a) Measure the worn depth of the chain vibration damper.
Maximum depth:
1.0 mm (0.039 in.)
If the depth is greater than the maximum, replace the chain vibration damper.
17. INSPECT NO. 2 CHAIN VIBRATION DAMPER

(a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder block and manifolds.
Standard warpage:

Maximum warpage:

If the warpage is greater than the maximum, replace the cylinder head assembly.

(b) Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks.
If cracked, replace the cylinder head assembly.
19. INSPECT INTAKE VALVE

(a) Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter:
5.470 to 5.485 mm (0.2154 to 0.2159 in.)
If the valve stem is not as specified, check the oil clearance.

(b) Using vernier calipers, measure the valve head margin thickness.
Standard margin thickness:
1.0 mm (0.03937 in.)
Minimum margin thickness:
0.5 mm (0.0197 in.)
If the margin thickness is less than the minimum, replace the intake valve.

(c) Using vernier calipers, measure the valve's overall length.
Standard overall length:
105.85 mm (4.1673 in.)
Minimum overall length:
105.35 mm (4.1476 in.)
If the overall length is less than the minimum, replace the intake valve.
20. INSPECT EXHAUST VALVE

(a) Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter:
5.465 to 5.480 mm (0.2151 to 0.2157 in.)
If the valve stem is not as specified, check the oil clearance.

(b) Using vernier calipers, measure the valve head margin thickness.
Standard margin thickness:
1.0 mm (0.0397 in.)
Minimum margin thickness:
0.5 mm (0.0197 in.)
If the margin thickness is less than the minimum, replace the exhaust valve.

(c) Using vernier calipers, measure the valve's overall length.
Standard overall length:
110.40 mm (4.3464 in.)
Minimum overall length:
109.90 mm (4.3268 in.)
If the overall length is less than the minimum, replace the exhaust valve.
21. INSPECT INTAKE VALVE SEAT
(a) Apply a light coat of Prussian blue (or white lead) to the valve face.
(b) Lightly press the valve face against the valve seat.

(c) Check the valve face and valve seat by using the following procedure.
(1) If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.
(2) If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat.
(3) Check that the valve seat contacts in the middle of the valve face with the width between 1.1 and 1.5 mm (0.043 and 0.059 in.).
22. INSPECT EXHAUST VALVE SEAT
(a) Apply a light coat of Prussian blue (or white lead) to the valve face.
(b) Lightly press the valve face against the valve seat.

(c) Check the valve face and valve seat by using to the following procedure.
(1) If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.
(2) If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat.
(3) Check that the valve seat contacts in the middle of the valve face with the width between 1.3 and 1.7 mm (0.051 and 0.067 in.).