Part 1
1GR-FE ENGINE MECHANICAL: ENGINE UNIT:
INSPECTION
1. INSPECT CAMSHAFTS
(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 runout:
0.06 mm (0.0024 in.)
If the circle runout is greater than the maximum, replace the camshaft.
(b) Inspect the cam lobes.
(1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake 44.168 to 44.268 mm (1.7389 to 1.7428 in.)
Exhaust 44.580 to 44.680 mm (1.7551 to 1.7591 in.)
Minimum cam lobe height:
Intake 44.018 mm (1.7330 in.)
Exhaust 44.430 mm (1.7492 in.)
If the cam lobe height is less than the minimum, replace the camshaft.
(c) Inspect the camshaft journals.
(1) Using a micrometer, measure the journal diameter.
No. 1 journal diameter:
35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Other journal diameter:
22.959 to 22.975 mm (0.9039 to 0.9045 in.)
If the journal diameter is not as specified, check the oil clearance.
2. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Fix the intake camshaft in a vise.
NOTE: Be careful not to damage the camshaft.
(b) Align the knock pin hole in the camshaft timing gear assembly with the knock pin of the camshaft, and install the camshaft timing gear assembly with the bolt.
Torque: 100 Nm (1,020 kgf-cm, 74 ft-lbf)
(c) Confirm that the camshaft timing gear assembly is locked.
(d) Release that lock pin.
(1) Cover 4 oil paths of cam journal with masking tape as shown in the illustration.
HINT: One of the 2 grooves on the cam journal is for the retard side path (upper) and the other is for the advance side path (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with a piece of rubber before wrapping the cam journal with tape.
(2) Puncture the tape covering the advance oil path and retard oil path on the opposite side of the groove as shown in the illustration.
(3) Apply air pressure into two broken paths (the advance side path and the retard side path) of about 200 kPa (2.0 kgf/cm2).
NOTE: Cover the paths with a shop rag to avoid oil splashes.
(4) Confirm that the camshaft timing gear assembly rotates in the timing advance direction when reducing the air pressure on the timing retard path.
HINT: When the lock pin is released, the camshaft timing gear rotates in the advance direction.
(5) When the camshaft timing gear comes to the most advanced position, release the air pressure on the timing retard side path, and release that of the timing advance side path.
NOTE: Camshaft timing assembly gear occasionally shifts to the retard side abruptly if the air compression on the advanced side path is released first. This often causes the breakage of the lock pin.
(e) Check the smooth revolution.
(1) Rotate the camshaft timing gear several times within the movable range except for the most retarded position and check it rotates smoothly.
Standard:
Move smoothly in the range about 31°
NOTE: Be sure to perform this check by hand, instead of using air pressure.
(f) Check that the lock is in the most retarded position.
(1) Confirm that the camshaft timing gear assembly is locked in the most retarded position.
(g) Remove the set bolt, then remove the camshaft timing gear assembly.
NOTE: Be sure not to remove the other 3 bolts.
3. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the outer diameter of the bolt thread.
Standard outer diameter:
10.85 to 11.00 mm (0.4272 to 0.4331 in.)
Minimum outer diameter:
10.7 mm (0.421 in.)
If the cylinder head set bolt is less than the minimum, replace the bolt.
4. INSPECT CHAIN SUB-ASSEMBLY
(a) Using a spring scale, apply 147 N (15.0 kgf, 33.1 lbf) to the chain and measure the length.
Maximum chain length:
146.8 mm (5.780 in.)
NOTE: Measure the length at least 3 places and calculate the average length.
If the chain length is greater than the maximum, replace the chain.
5. INSPECT NO.2 CHAIN SUB-ASSEMBLY
(a) Using a spring scale, apply 147 N (15.0 kgf, 33.1 lbf) to the chain and measure the length.
Maximum chain length:
146.8 mm (5.780 in.)
NOTE: Measure the length at least 3 places and calculate the average length.
If the chain length is greater than the maximum, replace the chain.
6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Wrap the No. 1 chain around the larger gear of timing gear assembly.
(b) Using vernier caliper, measure the timing gear with the chain wrapped.
Minimum gear diameter (with chain):
115.5 mm (4.547 in.)
NOTE: Vernier caliper must be in contact with the chain rollers when measuring.
If the gear diameter is less than the minimum, replace the No. 1 chain and the camshaft timing gear assembly.
(c) Wrap the No. 2 chain around the smaller gear of timing gear assembly.
(d) Using vernier calipers, measure the timing gear with the chain wrapped.
Minimum gear diameter (with chain):
73.1 mm (2.878 in.)
NOTE: The vernier calipers must be in contact the chain rollers when measuring.
If the gear diameter is less than the minimum, replace the No. 2 chain and the camshaft timing gear assembly.
7. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
(a) Wrap the No. 2 chain around the timing gear.
(b) Using vernier calipers, measure the camshaft timing gear diameter with the chain wrapped.
Minimum gear diameter (with chain):
73.1 mm (2.878 in.)
NOTE: The vernier calipers must be in contact the chain rollers when measuring.
If the gear diameter is less than the minimum, replace the No. 2 chain and camshaft timing gear.
8. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
(a) Wrap the No. 1 chain around the timing gear.
(b) Using vernier calipers, measure the timing gear diameter with the chain wrapped.
Minimum gear diameter (with chain):
61.0 mm (2.402 in.)
NOTE: The vernier calipers must be in contact with the chain rollers when measuring.
If the gear diameter is less than the minimum, replace the No. 1 chain and the crankshaft timing gear.
9. INSPECT IDLE SPROCKET ASSEMBLY
(a) Wrap the No. 1 chain around the idle sprocket.
(b) Using vernier caliper, measure the idle sprocket with the chain wrapped.
Minimum gear diameter (with chain):
61.0 mm (2.402 in.)
NOTE: The vernier caliper must be in contact with the chain rollers when measuring.
If the gear diameter is less than the minimum, replace the No. 1 chain and idle sprocket.
10. INSPECT NO.1 IDLE GEAR SHAFT
(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 internal diameter of the idle gear.
Idle gear internal diameter:
23.02 to 23.03 mm (0.9063 to 0.9067 in.)
(c) Subtract the idle gear shaft diameter measurement from the idle gear internal 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.)
11. INSPECT NO.1 CHAIN TENSIONER ASSEMBLY
(a) Check that the plunger moves smoothly when the ratchet pawl is raised with finger.
(b) Release the ratchet pawl, then check that the plunger is locked in place by the ratchet pawl and does not move when pushing it with finger.
12. INSPECT NO.2 CHAIN TENSIONER ASSEMBLY
(a) Check that the plunger moves smoothly.
(b) Measure the wear of the chain tensioner slipper.
Maximum wear:
1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the chain tensioner No. 2.
13. INSPECT NO.3 CHAIN TENSIONER ASSEMBLY
(a) Check that the plunger moves smoothly.
(b) Measure the wear of the chain tensioner slipper.
Maximum wear:
1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the chain tensioner No. 3.
14. INSPECT CHAIN TENSIONER SLIPPER
(a) Measure the wear of the tensioner slipper.
Maximum wear:
1.0 mm (0.039 in.)
If the thickness is greater than the maximum, replace the tensioner slipper.
15. INSPECT NO.1 CHAIN VIBRATION DAMPER
(a) Measure the wear of the vibration damper No. 1.
Maximum wear:
1.0 mm (0.039 in.)
If the thickness is greater than the maximum, replace the vibration damper No. 1.
16. INSPECT NO.2 CHAIN VIBRATION DAMPER
(a) Measure the wear of the vibration damper No. 2.
Maximum wear:
1.0 mm (0.039 in.)
If the thickness is greater than the maximum, replace the vibration damper No. 2.
17. INSPECT CYLINDER HEAD SUB-ASSEMBLY
(a) Inspect the cylinder head for warpage.
(1) Using a precision straight edge and feeler gauge, measure the warpage on the cylinder block side and the intake and exhaust sides.
Maximum warpage:
0.10 mm (0.0039 in.)
If the warpage is greater than the maximum, replace the cylinder head.
(b) Inspect the cylinder head for crack.
(1) Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.
18. CLEAN VALVE
(a) Using a gasket scraper, chip off any carbon from the valve head.
(b) Using a wire brush, thoroughly clean the valve.
19. INSPECT VALVE
(a) Inspect valve stem diameter.
(1) Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter:
(b) Inspect valve face angle.
(1) Grind the valve enough to remove any pits and carbon.
(2) Check that the valve is ground to the correct valve face angle.
Valve face angle:
45.5°
(c) Inspect valve head margin thickness.
(1) Using vernier calipers, check the valve head margin thickness.
Standard margin thickness:
1.0 mm (0.039 in.)
Minimum margin thickness:
0.5 mm (0.020 in.)
If the margin thickness is less than the minimum, replace the valve.
(d) Inspect overall length.
(1) Using vernier calipers, check the overall length.
Standard overall length:
Minimum overall length:
If the overall length is less than the minimum, replace the valve.
(e) Inspect valve stem tip.
(1) Check the surface of the valve stem tip for wear.
NOTE: Do not grind to less than the minimum length.
If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.
20. CLEAN VALVE SEAT
(a) Using a 45° carbide cutter, resurface the valve seats.
(b) Clean the valve seats.
