Part 1

2TR-FE ENGINE MECHANICAL: ENGINE UNIT:

INSPECTION

1. INSPECT CHAIN SUB-ASSEMBLY
(a) Pull the chain with a force of 147 N (15 kgf, 33 Ibf) as shown in the illustration.
(b) Using vernier calipers, measure the length of 16 links.
Maximum chain elongation:
147.5 mm (5.807 in.)
If the elongation is greater than the maximum, replace the chain.

NOTE: Perform the same measurement by pulling at random in 3 or more places to obtain an average.

2. INSPECT NO.2 CHAIN SUB-ASSEMBLY
(a) Pull the chain with a force of 147 N (15 kgf, 33 Ibf) as shown in the illustration.
(b) Using vernier calipers, measure the length of 16 links.
Maximum chain elongation:
123.6 mm (4.866 in.)
If the elongation is greater than the maximum, replace the chain.

NOTE: Perform the same measurement by pulling at random in 3 or more places to obtain an average.

3. 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.

4. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Move the stopper plate downward to release the lock. Push the plunger and check that it moves smoothly.

5. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
(a) Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip.
Minimum distance:
1.0 mm (0.039 in.)
If the distance is less than the minimum, replace the sprocket.

HINT: If the worn area is too small or difficult to distinguish from a normal area, perform steps (b) and (c) below.

(b) Wrap the chain around the sprocket.
(c) Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain):
113.8 mm (4.480 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.

6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Measure the distance between the most worn out timing gear tip and the beginning of the worn area below the tip.
Minimum distance:
1.0 mm (0.039 in.)
If the distance is less than the minimum, replace the timing gear.

HINT: If the worn area is too small or difficult to distinguish from a normal area, perform steps (b) and (c) below.

(b) Wrap the chain around the timing gear.
(c) Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain):
113.8 mm (4.480 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 timing gear.

7. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
(a) Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip.
Minimum distance:
1.0 mm (0.039 in.)
If the distance is less than the minimum, replace the sprocket.

HINT: If the worn area is too small or difficult to distinguish from a normal area, perform steps (b) and (c) below.

(b) Wrap the chain around the drive sprocket.
(c) Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain):
59.4 mm (2.338 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.

8. INSPECT CHAIN TENSIONER SLIPPER
(a) Using vernier calipers, measure the tensioner slipper wear.
Maximum wear:
2.0 mm (0.079 in.)
If the wear is greater than the maximum, replace the tensioner slipper.

9. INSPECT NO. 1 CHAIN VIBRATION DAMPER
(a) Using vernier calipers, measure the vibration damper wear.
Maximum wear:
2.0 mm (0.079 in.)
If the wear is greater than the maximum, replace the vibration damper.

10. INSPECT TIMING CHAIN GUIDE
(a) Using vernier calipers, measure the chain guide wear.
Maximum wear:
0.5 mm (0.020 in.)
If the wear is greater than the maximum, replace the timing chain guide.

11. INSPECT NO. 2 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):
96.7 mm (3.807 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.

12. INSPECT BALANCESHAFT DRIVE GEAR SUB-ASSEMBLY
(a) Wrap the chain around the sprocket.
(b) Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain):
75.9 mm (2.988 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.

13. INSPECT NO. 2 CHAIN VIBRATION DAMPER
(a) Using vernier calipers, measure the vibration damper No.2 wear.
Maximum wear:
1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the vibration damper.

14. INSPECT NO. 3 CHAIN VIBRATION DAMPER
(a) Using vernier calipers, measure the vibration damper No.3 wear.
Maximum wear:
1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the vibration damper.

15. INSPECT NO. 4 CHAIN VIBRATION DAMPER
(a) Using vernier calipers, measure the vibration damper No.4 wear.
Maximum wear:
1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the vibration damper.

16. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point.
Standard outside diameter:
10.76 to 10.97 mm (0.4236 to 0.4319 in.)
Minimum outside diameter:
10.40 mm (0.4094 in.)

HINT:
- If a visual check reveals no excessively thin areas, check the center of the bolt (see illustration) and find the area that has the lowest diameter.
- If the diameter is less than the minimum, replace the cylinder head bolt.

17. INSTALL CRANKSHAFT PULLEY SET CRANKSHAFT KEY
(a) Install the 2 pulley keys to the crankshaft.

18. INSTALL NO. 4 CHAIN VIBRATION DAMPER
(a) Install the vibration damper No.4 with the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft-lbf)

19. INSPECT VALVE LASH ADJUSTER ASSEMBLY

- Keep the lash adjuster free from dirt and foreign objects.
- Only use clean engine oil.

(a) Place the lash adjuster into a container full of engine oil.
(b) Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the checkball 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 checkball as shown in the illustration. If the checkball is not pressed, air will not bleed.

(e) After bleeding the air, remove the SST. Then 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.

20. INSPECT CYLINDER HEAD FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of contacting the cylinder block and manifolds.
Maximum warpage:
0.05 mm (0.0020 in.)
If the warpage is greater than the maximum, replace the cylinder head.

21. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrate, check the intake ports, exhaust ports and cylinder surface for cracks.
If cracked, replace the cylinder head.

22. 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.).

23. 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 1.0 and 1.4 mm (0.039 and 0.055 in.).
24. INSPECT CAMSHAFT

(a) Check 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:
0.03 mm (0.0012 in.)
If the circle runout is greater than the maximum, replace the camshaft.

(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
42.855 to 42.955 mm (1.6872 to1.6911 in.)
Minimum cam lobe height:
42.855 mm (1.6872 in.)
If the cam lobe height is less than the minimum, replace the camshaft.

If the journal diameter is not as specified, check the oil clearance.
25. INSPECT NO.2 CAMSHAFT

(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
42.854 to 42.954 mm (1.687 to 1.6911 in.)
Minimum cam lobe height:
42.854 mm (1.6872 in.)
If the cam lobe height is less than the minimum, replace the camshaft.

If the journal diameter is not as specified, check the oil clearance.