Engine Unit

2GR-FXE 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 No. 1 valve rocker arm sub-assembly.

2. INSPECT VALVE LASH ADJUSTER ASSEMBLY

NOTICE:
* 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 new engine oil.

Text in Illustration

(b) Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

SST : 09276-75010

(c) Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times.

(d) Check the movement of the plunger and bleed 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 your fingers.

OK:

Plunger can be pressed 3 times.

If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster with a new one.

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 runout:

0.04 mm (0.00157 in.)

If the runout is more 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:

Minimum Cam Lobe Height:

If the cam lobe height is less than the minimum, replace the camshaft.

(c) Using a micrometer, measure the journal diameter.

Standard Journal Diameter:

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

4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

(a) Fix the camshaft in place.

NOTICE:
Be careful not to damage the camshaft.

(b) Put the camshaft timing gear assembly and camshaft together by aligning the pin hole and straight pin.

Text in Illustration

(c) Lightly press and turn the camshaft timing gear assembly against the camshaft and press harder after the pin enters the hole.

NOTICE:
Be sure not to turn the camshaft timing gear assembly in the retard direction.

(d) Check that there is no clearance between the camshaft timing gear assembly flange and the camshaft.

(e) Install the flange bolt while holding the camshaft.

Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)

(f) Check the lock of the camshaft timing gear assembly.

(1) Fix the camshaft in place and confirm that the camshaft timing gear assembly 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.

Text in Illustration

HINT
The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a piece of rubber.

(2) Break through the tape over the advance side path and the tape over the retard side path on the opposite side of 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 2 opened paths.

Text in Illustration

CAUTION:
Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.

(4) Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path.

Text in Illustration

HINT
This operation releases the lock pin at the most retarded position.

(5) When the camshaft timing gear assembly reaches the most advanced position, release the air pressure from the retard side path first, and then from the advance side path.

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 assembly 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 assembly locks at the most retarded position.

(j) Remove the flange bolt and camshaft timing gear assembly.

Text in Illustration

NOTICE:
* Do not remove the other 3 bolts.
* If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear.

5. INSPECT CYLINDER HEAD SET BOLT

(a) Using a vernier caliper, measure the diameter of the threads at the measurement point shown in the illustration.

Distance:

103 mm (4.06 in.)

Standard diameter:

10.85 to 11.00 mm (0.427 to 0.433 in.)

Minimum diameter:

10.70 mm (0.421 in.)

Text in Illustration

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

6. INSPECT CHAIN SUB-ASSEMBLY

(a) Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33 lbf) and measure the length of the chain using a vernier caliper.

Maximum chain elongation:

136.9 mm (5.39 in.)

Text in Illustration

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

If the average is more than the maximum, replace the chain.

7. INSPECT NO. 2 CHAIN SUB-ASSEMBLY

(a) Using a spring scale, pull the No. 2 chain with a force of 147 N (15 kgf, 33 lbf) and measure the length of the No. 2 chain using a vernier caliper.

Maximum chain elongation:

137.6 mm (5.42 in.)

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

If the average is more than the maximum, replace the chain.

8. INSPECT CRANKSHAFT TIMING SPROCKET

(a) Place the chain around the sprocket.

(b) Using a vernier caliper, measure the sprocket diameter together with the chain sub-assembly.

Minimum sprocket diameter (with chain):

61.4 mm (2.42 in.)

HINT
The vernier caliper must contact the chain rollers for the measurement.

If the diameter is less than the minimum, replace the No. 1 chain and sprocket.

9. INSPECT IDLE SPROCKET ASSEMBLY

(a) Place the chain around the sprocket.

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

Minimum sprocket diameter (with chain):

61.4 mm (2.42 in.)

HINT
The vernier caliper must contact the chain rollers for the measurement.

If the diameter is less than the minimum, replace the No. 1 chain and sprocket.

10. 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 (0.9050 to 0.9055 in.)

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

Standard 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 sprocket inside diameter measurement.

Standard oil clearance:

0.020 to 0.043 mm (0.000787 to 0.00169 in.)

Maximum oil clearance:

0.093 mm (0.00366 in.)

If the oil clearance is more than the maximum, replace the idle gear shaft and idle sprocket assembly.

11. 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 No. 1 chain tensioner assembly.

12. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Check that the plunger moves smoothly.

(b) Measure the depth of wear of the No. 2 chain tensioner assembly.

Maximum depth:

0.9 mm (0.0354 in.)

Text in Illustration

If the depth is more than the maximum, replace the No. 2 chain tensioner assembly.

13. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Check that the plunger moves smoothly.

(b) Measure the depth of wear of the No. 3 chain tensioner assembly.

Maximum depth:

0.9 mm (0.0354 in.)

Text in Illustration

If the depth is more than the maximum, replace the No. 3 chain tensioner assembly.

14. INSPECT CHAIN TENSIONER SLIPPER

(a) Measure the depth of wear of the chain tensioner slipper.

Maximum depth:

1.0 mm (0.0394 in.)

Text in Illustration

If the depth is more than the maximum, replace the chain tensioner slipper.

15. INSPECT NO. 1 CHAIN VIBRATION DAMPER

(a) Measure the depth of wear of the No. 1 chain vibration damper.

Maximum depth:

1.0 mm (0.0394 in.)

Text in Illustration

If the depth is more than the maximum, replace the No. 1 chain vibration damper.

16. INSPECT NO. 2 CHAIN VIBRATION DAMPER

(a) Measure the depth of wear of the No. 2 chain vibration damper.

Maximum depth:

1.0 mm (0.0394 in.)

Text in Illustration

If the depth is more than the maximum, replace the No. 2 chain vibration damper.

17. INSPECT CAMSHAFT OIL CLEARANCE

(a) for Bank 1:

(1) Clean the camshaft bearing caps, camshaft housing and camshaft journals.

(2) Place the camshafts on the camshaft housing.

(3) Lay a strip of Plastigage across each camshaft journal.

Text in Illustration

(4) Install the camshaft bearing caps Installation.

NOTICE:
Do not turn the camshaft.

(5) Remove the camshaft bearing caps Removal.

(6) Measure the Plastigage at its widest point.

Standard Oil Clearance:

Maximum Oil Clearance:

Text in Illustration

If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the camshaft housing.

(b) for Bank 2:

(1) Clean the camshaft bearing caps, camshaft housing and camshaft journals.

(2) Place the camshafts on the camshaft housing.

(3) Lay a strip of Plastigage across each camshaft journal.

Text in Illustration

(4) Install the camshaft bearing caps Installation.

NOTICE:
Do not turn the camshaft.

(5) Remove the camshaft bearing caps Removal.

(6) Measure the Plastigage at its widest point.

Standard Oil Clearance:

Maximum Oil Clearance:

Text in Illustration

If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the camshaft housing sub-assembly.

18. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH

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

Maximum warpage:

0.7 mm (0.0276 in.)

HINT
The maximum allowable warpage of each installation surface is 0.7 mm (0.0276 in.).

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

19. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH

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

(1) Using a precision straightedge and feeler gauge, measure the surface that contacts the cylinder head for warpage.

Maximum warpage:

0.1 mm (0.00394 in.)

Text in Illustration

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

(b) Surge tank side:

(1) Using a precision straightedge and feeler gauge, measure the surface that contacts the surge tank for warpage.

Maximum warpage:

0.1 mm (0.00394 in.)

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