Part 2

4GR-FSE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (Continued)

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.

(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.

11. INSPECT IDLE GEAR SHAFT OIL CLEARANCE

(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) 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.

15. INSPECT CHAIN TENSIONER SLIPPER

(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) 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.

18. INSPECT CYLINDER HEAD ASSEMBLY

(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:

106.15 mm (4.1791 in.)

Minimum overall length:

105.65 mm (4.1594 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:

0.81 mm (0.0319 in.)

Minimum margin thickness:

0.31 mm (0.0122 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:

111.70 mm (4.3976 in.)

Minimum overall length:

111.20 mm (4.3779 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 1.0 and 1.4 mm (0.039 and 0.055 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.