Engine Unit

2GR-FSE ENGINE MECHANICAL: ENGINE UNIT: 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 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.

NOTICE:
When bleeding high-pressure air from the compression chamber, make sure that the tip of 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 (0.00157 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:

Standard Journal Diameter:

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.

NOTICE:
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.

Text in Illustration

(c) Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.

NOTICE:
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 secured.

Torque : 100 Nm (1020 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.

NOTICE:
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.

Text in Illustration

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.

NOTICE:
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.

NOTICE:
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.

NOTICE:
* 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.

NOTICE:
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.

Text in Illustration

(c) Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.

NOTICE:
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 secured.

Torque : 100 Nm (1020 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).

Text in Illustration

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.

NOTICE:
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.

NOTICE:
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.

NOTICE:
* 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 a vernier caliper, measure the diameter of the thread at the measurement point.

Standard diameter:

10.85 to 11.00 mm (0.4272 to 0.4330 in.)

Minimum diameter:

10.70 mm (0.4212 in.)

Measurement point (distance from the seat):

100 mm (3.94 in.)

HINT
* If there is any thread deformation, replace the cylinder head bolt with a new one.
* If the diameter is less than the minimum, replace the cylinder head set bolt. Failure to do so may lead to engine damage.

7. INSPECT CHAIN SUB-ASSEMBLY

(a) Pull the chain sub-assembly with a force of 147 N (15 kgf, 33.1 lbf) as shown in the illustration.

(b) Using a vernier caliper, measure the length of 15 links.

Maximum chain elongation:

136.9 mm (5.389 in.)

NOTICE:
Perform the measurement at 3 random places. Use the average of the measurements.

If the average elongation is greater than the maximum, replace the chain sub-assembly.

8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY

(a) Pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33.1 lbf) as shown in the illustration.

(b) Using a vernier caliper, measure the length of 15 links.

Maximum chain elongation:

137.6 mm (5.417 in.)

NOTICE:
Perform the measurement at 3 random places. Use the average of the measurements.

If the average elongation is greater than the maximum, replace the chain sub-assembly.

9. INSPECT CRANKSHAFT TIMING SPROCKET

(a) Place the chain around the crankshaft timing sprocket.

(b) Using a vernier caliper, measure the sprocket diameter with the chain.

Minimum sprocket diameter (with chain):

61.4 mm (2.417 in.)

HINT
The vernier caliper 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) Place the chain around the idle sprocket.

(b) Using a vernier caliper, measure the sprocket diameter with the chain.

Minimum sprocket diameter (with chain):

61.4 mm (2.417 in.)

HINT
The vernier caliper 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.

Standard idle gear shaft diameter:

22.987 to 23.000 mm (0.90500 to 0.90551 in.)

(b) Using a caliper gauge, measure the inside diameter of the idle gear.

Standard idle gear inside diameter:

23.020 to 23.030 mm (0.90630 to 0.90669 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 (0.00078 to 0.00169 in.)

Maximum oil clearance:

0.093 mm (0.00366 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.

Text in Illustration

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 (0.0354 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 (0.0354 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 (0.0394 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 (0.0394 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 (0.0394 in.)

If the depth is greater than the maximum, replace the chain vibration damper.

18. 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 (0.00315 to 0.00512 in.)

Maximum thrust clearance:

0.15 mm (0.00591 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 (0.00315 to 0.00512 in.)

Maximum thrust clearance:

0.15 mm (0.00591 in.)

If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

19. 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.

Text in Illustration

(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.

Text in Illustration

(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.

20. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

Maximum warpage:

0.7 mm (0.02756 in.)

HINT
The maximum allowable warpage of each installation surface is 0.3 mm (0.01181 in.).

If the warpage is greater than the maximum, replace the manifold.

21. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

(1) Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

Maximum warpage:

0.1 mm (0.00394 in.)

If the warpage is greater than the maximum, replace the intake manifold.

(b) Cylinder head side:

(1) Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

Maximum warpage:

0.1 mm (0.00394 in.)

If the warpage is greater than the maximum, replace the intake manifold.