Part 2

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION - Continued

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 (0.9050 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 thrust oil clearance is greater than the maximum, replace the idle gear shaft and idle sprocket assembly.

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 No. 1 chain tensioner assembly.

13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Check that the plunger moves smoothly.

Text in Illustration

(b) Using a vernier caliper, measure the worn depth of the No. 2 chain tensioner assembly.

Maximum depth:

0.9 mm (0.0354 in.)

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

14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Check that the plunger moves smoothly.

Text in Illustration

(b) Using a vernier caliper, measure the worn depth of the No. 3 chain tensioner assembly.

Maximum depth:

0.9 mm (0.0354 in.)

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

15. INSPECT CHAIN TENSIONER SLIPPER

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

Text in Illustration

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) Using a vernier caliper, measure the worn depth of the No. 1 chain vibration damper.

Text in Illustration

Maximum depth:

1.0 mm (0.0394 in.)

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

17. INSPECT NO. 2 CHAIN VIBRATION DAMPER

(a) Using a vernier caliper, measure the worn depth of the No. 2 chain vibration damper.

Text in Illustration

Maximum depth:

1.0 mm (0.0394 in.)

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

18. INSPECT CAMSHAFT THRUST CLEARANCE

(a) Inspect the bank 1 camshaft thrust clearance.

(1) Install the bank 1 camshaft Installation.

(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 bank 2 camshaft thrust clearance.

(1) Install the bank 2 camshaft Installation.

(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 (for Bank 1)

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

(b) Place the camshafts on the camshaft housing.

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

Text in Illustration

(d) Install the camshaft bearing caps Installation.

NOTICE:
Do not turn the camshaft.

(e) Remove the camshaft bearing caps Removal.

(f) Measure the Plastigage at its widest point.

Text in Illustration

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 CAMSHAFT OIL CLEARANCE (for Bank 2)

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

(b) Place the camshafts on the camshaft housing.

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

Text in Illustration

(d) Install the camshaft bearing caps Installation.

NOTICE:
Do not turn the camshaft.

(e) Remove the camshaft bearing caps Removal.

(f) Measure the Plastigage at its widest point.

Text in Illustration

Standard Oil Clearance:

Maximum Oil Clearance:

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

21. 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 (0.0276 in.)

HINT
The maximum allowable warpage of each installation surface is 0.3 mm (0.0118 in.).

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

22. 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.

Text in Illustration

(a) Cylinder head side:

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

Maximum warpage:

0.1 mm (0.00394 in.)

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

(b) Surge tank side:

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

Maximum warpage:

0.1 mm (0.00394 in.)

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