Engine Unit

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION

INSPECTION

1. INSPECT CAMSHAFTS Testing and Inspection
2. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY Testing and Inspection
3. INSPECT CYLINDER HEAD SET BOLT Testing and Inspection





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 in 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 in 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 chain sub-assembly around the larger gear of the timing gear assembly.
(b) Using vernier calipers, measure the timing gear with the chain wrapped.
Minimum gear diameter (with chain):
115.5 mm (4.547 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 chain sub-assembly 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 chain sub-assembly 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 chain sub-assembly and the crankshaft timing gear.





9. INSPECT IDLE SPROCKET ASSEMBLY
(a) Wrap the chain sub-assembly around the idle sprocket.
(b) Using vernier calipers, measure the idle sprocket 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 chain sub-assembly 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.)
If the result is not as specified, replace the idle gear shaft.





(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.)
If the result is not as specified, replace the idle gear.
(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.)
If the oil clearance is greater than the maximum, replace the idle gear or gear shaft.





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.
If the results are not as specified, replace the No. 1 chain tensioner assembly.





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 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 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 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 vibration damper No. 2.
17. CLEAN CYLINDER HEAD SUB-ASSEMBLY Testing and Inspection
18. INSPECT CYLINDER HEAD SUB-ASSEMBLY Testing and Inspection
19. CLEAN VALVE Testing and Inspection
20. INSPECT VALVE Testing and Inspection
21. CLEAN VALVE SEAT Testing and Inspection
22. INSPECT VALVE SEAT Testing and Inspection
23. INSPECT INNER COMPRESSION SPRING Testing and Inspection
24. INSPECT VALVE GUIDE BUSH OIL CLEARANCE Testing and Inspection
25. INSPECT VALVE LIFTER Testing and Inspection
26. INSPECT VALVE LIFTER OIL CLEARANCE Testing and Inspection





27. CHECK CYLINDER BLOCK FOR WARPAGE
(a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.
Maximum warpage:
0.05 mm (0.0020 in.)
If the warpage is greater than the maximum, replace the cylinder block.





28. INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
Standard diameter:
94.000 to 94.012 mm (3.7008 to 3.7013 in.)
Maximum diameter:
94.132mm (3.7060 in.)
If the average diameter of the 4 positions is greater than the maximum, replace the cylinder block.





29. INSPECT WITH PISTON SUB-ASSEMBLY
(a) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 27.7 mm (1.091 in.) from the piston head.
Piston diameter:
93.910 to 93.940 mm (3.6972 to 3.6984 in.)
If the result is not as specified, replace the with piston sub-assembly.
30. INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance:
0.060 to 0.102 mm (0.0031 to 0.0040 in.)
Maximum oil clearance:
0.13 mm (0.0051 in.)
If the oil clearance is greater than the maximum, replace all the 6 pistons. If necessary, replace the cylinder block.
31. INSPECT CONNECTING ROD SUB-ASSEMBLY





(a) Using a rod aligner and feeler gauge, check the connecting rod alignment.
(1) Check for misalignment.
Maximum misalignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If misalignment is greater than the maximum, replace the connecting rod assembly.




(2) Check the twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum, replace the connecting rod assembly.
32. INSPECT PISTON PIN OIL CLEARANCE





(a) Using a caliper gauge, measure the internal diameter of the piston pin hole.
Piston pin hole internal diameter:
22.001 to 22.010 mm (0.8662 to 0.8665 in.)
Piston pin hole inside diameter:










(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 to 22.006 mm (0.8660 to 0.8664 in.)
Piston pin diameter:










(c) Using a caliper gauge, measure the internal diameter of the connecting rod bushing.
Bushing internal diameter:
22.005 to 22.014 mm (0.8663 to 0.8667 in.)
Bushing internal diameter:






(d) Subtract the piston pin diameter measurement from the piton pin hole diameter measurement.
Standard oil clearance:
0.001 to 0.007 mm (0.00004 to 0.00028 in.)
Maximum oil clearance:
0.040 mm (0.0016 in.)





(e) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the piston and piston pin together.
(f) Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Standard oil clearance:
0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance:
0.050 mm (0.0020 in.)
(g) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin together.





33. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.
Ring groove clearance:






34. INSPECT PISTON RING END GAP





(a) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block.





(b) Using a feeler gauge, measure the end gap.
Standard end gap:






Maximum end gap:










35. INSPECT CONNECTING ROD BOLT
(a) Using vernier calipers, measure the diameter of the elongated portion of the bolt.
Standard diameter:
7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter:
7.0 mm (0.276 in.)
If the diameter is less than the minimum, replace the bolt.





36. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using vernier calipers, measure the diameter of the elongated portion of the bolt.
Standard diameter:
10.0 to 10.2 mm (0.393 to 0.402 in.)
If the diameter is less than the minimum, replace the bolt.
37. INSPECT CRANKSHAFT





(a) Using a dial indicator and V-blocks, measure the runout as shown in the illustration.
Maximum circle runout:
0.06 mm (0.0024 in.)
If the result is not as specified, replace the crankshaft.





(b) Using a micrometer, measure the diameter of each main journal.
Standard Diameter:
71.988 to 72.000 mm (2.8342 to 2.8346 in.)
If the result is not as specified, replace the crankshaft.
(c) Check each main journal for taper and out-of-roundness as shown.
Maximum taper and out-of-roundness:
0.02 mm (0.0008 in.)
If the result is not as specified, replace the crankshaft.





(d) Using a micrometer, measure the diameter of each crank pin.
Standard diameter:
55.992 to 56.000 mm (2.2044 to 2.2047 in.)
If the result is not as specified, replace the crankshaft.
(e) Check each crank pin for taper and out-of-roundness as shown.
Maximum taper and out-of-roundness:
0.02 mm (0.0008 in.)
If the result is not as specified, replace the crankshaft.