Part 3
2GR-FSE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (Continued)
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.).
23. REPAIR INTAKE VALVE SEAT
NOTICE:
* Repair the seat while checking the seating position.
* Keep the lip free of foreign matter.
(a) Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification.
(b) Using 30° and 60° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat.
Width:
1.1 to 1.5 mm (0.043 to 0.059 in.)
(c) Hand rub the valve and valve seat with an abrasive compound.
(d) Check the valve seating position.
24. REPAIR EXHAUST VALVE SEAT
NOTICE:
* Repair the seat while checking the seating position.
* Keep the lip free of foreign matter.
(a) Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification.
(b) Using 30° and 75° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat.
Width:
1.3 to 1.7 mm (0.051 to 0.067 in.)
(c) Hand rub the valve and valve seat with an abrasive compound.
(d) Check the valve seating position.
25. INSPECT INNER COMPRESSION SPRING
(a) Using vernier calipers, measure the free length of the inner compression spring.
Free length:
49.73 mm (1.958 in.)
If the free length is not as specified, replace the spring.
(b) Using a steel square, measure the deviation of the inner compression spring.
Maximum deviation:
1.0 mm (0.039 in.)
If the deviation is greater than the maximum, replace the spring.
26. INSPECT VALVE GUIDE BUSH OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the guide bush.
Bush inside diameter:
5.510 to 5.530 mm (0.2169 to 0.2177 in.)
(b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.
Standard clearance:
Maximum oil clearance:
For intake side:
If the clearance is greater than the maximum, replace the intake valve and intake guide bush.
For exhaust side:
If the clearance is greater than the maximum, replace the exhaust valve and exhaust guide bush.
27. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Inspect the RH bank camshaft thrust clearance.
(1) Install the RH bank camshafts Reassembly.
(2) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance:
0.08 to 0.13 mm (0.0031 to 0.0051 in.)
Maximum thrust clearance:
0.15 mm (0.006 in.)
If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.
(b) Inspect the LH bank camshaft thrust clearance.
(1) Install the LH bank camshafts Reassembly.
(2) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance:
0.08 to 0.13 mm (0.0031 to 0.0051 in.)
Maximum thrust clearance:
0.15 mm (0.006 in.)
If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.
28. INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the bearing caps, camshaft housing and camshaft journals.
(b) Place the camshafts on the camshaft housing.
(c) Lay a strip of Plastigage across each of the camshaft journals.
(d) Install the bearing caps Reassembly.
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps Disassembly.
(f) Measure the Plastigage at its widest point.
Standard oil clearance:
Maximum oil clearance:
If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.
(g) Clean the bearing caps, camshaft housing and camshaft journals.
(h) Place the camshafts on the camshaft housing.
(i) Lay a strip of Plastigage across each of the camshaft journals.
(j) Install the bearing caps Reassembly.
NOTICE:
Do not turn the camshaft.
(k) Remove the bearing caps Disassembly.
(l) Measure the Plastigage at its widest point.
Standard oil clearance:
Maximum oil clearance:
If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.
29. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Install the connecting rod cap Reassembly.
(b) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance:
0.15 to 0.40 mm (0.0059 to 0.0157 in.)
Maximum thrust clearance:
0.50 mm (0.020 in.)
If the thrust clearance is greater than the maximum, replace the connecting rod assemblies as necessary. If necessary, replace the crankshaft.
30. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Clean the crank pin and bearing.
(b) Check the crank pin and bearing for pitting and scratches.
(c) Lay a strip of Plastigage on the crank pin.
(d) Check that the front mark of the connecting rod cap is facing forward.
(e) Install the connecting rod cap Reassembly.
NOTICE:
Do not turn the crankshaft.
(f) Remove the 2 bolts and connecting rod cap Disassembly.
(g) Measure the Plastigage at its widest point.
Standard oil clearance:
0.045 to 0.067 mm (0.0018 to 0.0026 in.)
Maximum oil clearance:
0.070 mm (0.0028 in.)
If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.
HINT
If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, 3 and 4 mark on its surface.
Connecting rod diameter:
Connecting rod bearing center wall thickness:
Crankshaft pin diameter:
52.992 to 53.000 mm (2.0863 to 2.0866 in.)
NOTICE:
Completely remove the Plastigage after the measurement.
31. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Install the main bearing cap Reassembly.
(b) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.04 to 0.24 mm (0.0016 to 0.0094 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.
Thrust washer thickness:
2.43 to 2.48 mm (0.0957 to 0.0976 in.)