Engine Unit

1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION

1. INSPECT CYLINDER HEAD SET BOLT

(a) Using a vernier caliper, measure the length of the cylinder head set bolt from the seat to the end.

Standard length:

141.3 to 142.7 mm (5.56 to 5.62 in.)

Maximum length:

143.7 mm (5.66 in.)

(b) If the length is more than the maximum, replace the cylinder head set bolt.

(c) Using a vernier caliper, measure the diameter of the elongated thread at the narrowest visible area.

Standard diameter:

10.73 to 10.97 mm (0.422 to 0.432 in.)

Minimum diameter:

10.40 mm (0.409 in.)

(d) If the diameter is less than the minimum, replace the cylinder head set bolt.

HINT
If a visual check reveals no excessively thin areas, check the center of the bolt (refer to illustration) and find the area that has the smallest diameter.

2. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

(a) Turn the roller by hand to check that it turns smoothly.

If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.

3. INSPECT VALVE LASH ADJUSTER ASSEMBLY

NOTICE:
* Keep the valve lash adjuster assembly free of dirt and foreign objects.
* Only use clean engine oil.
(a) Place the valve lash adjuster assembly into a container filled with engine oil.

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

SST : 09276-75010

(c) Squeeze SST and the valve lash adjuster assembly 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.

NOTICE:
When bleeding air from the high-pressure 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 by hand.

OK:

Plunger is very difficult to move.

(f) If the result is not as specified, replace the valve lash adjuster assembly.

4. INSPECT CAMSHAFT

(a) Inspect the camshaft 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.)

(3) 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:

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

5. 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.

(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 camshaft.

(e) Tighten 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.

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

(2) Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration.

(3) Apply air at approximately 200 kPa (2.0 kgf/cm2, 28 psi) to the 2 open paths.

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.

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 first from the retard side path and next 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.

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.
6. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

(a) Fix the camshaft in place.

NOTICE:
Be careful not to damage the camshaft.

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

(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 exhaust gear in the advanced direction.

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

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

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

(f) Check the camshaft timing exhaust gear lock.

(1) Make sure that the camshaft timing exhaust gear assembly locks.

(g) Release the lock pin.

(1) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

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

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

HINT
The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.

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

NOTICE:
Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.

(h) Check for smooth rotation.

(1) Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear assembly turns smoothly.

NOTICE:
When the air pressure is released from the advance side path and then from the retard side path, the gear assembly automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

(i) Check the lock at the most advanced position.

(1) Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position.

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

NOTICE:
* Be sure not to remove the other 4 bolts.
* If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.
7. INSPECT NO. 1 CHAIN SUB-ASSEMBLY

(a) Using a spring scale, pull the No. 1 chain with a force of 147 N (15 kgf, 33 lbf) and measure the length of the No. 1 chain using a vernier caliper.

Maximum chain elongation:

136.9 mm (5.39 in.)

HINT
Perform the measurement at 3 random places.

(b) If a measurement is more than the maximum, replace the No. 1 chain.

8. 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.

(b) If a measurement is more than the maximum, replace the No. 2 chain.

9. INSPECT CRANKSHAFT TIMING SPROCKET

(a) Wrap the No. 1 chain around the sprocket.

(b) Using a vernier caliper, measure the crankshaft timing sprocket diameter with the No. 1 chain.

Minimum gear diameter (with chain):

61.0 mm (2.40 in.)

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

(c) If the diameter is less than the minimum, replace the No. 1 chain and crankshaft timing sprocket.

10. INSPECT NO. 1 IDLE GEAR

(a) Wrap the No. 1 chain around the gear.

(b) Using a vernier caliper, measure the No. 1 idle gear diameter with the No. 1 chain.

Minimum gear diameter (with chain):

61.0 mm (2.40 in.)

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

(c) If the diameter is less than the minimum, replace the No. 1 chain and No. 1 idle gear.

11. INSPECT NO. 1 IDLE GEAR SHAFT OIL CLEARANCE

(a) Using a micrometer, measure the No. 1 idle gear shaft diameter.

Standard idle gear shaft diameter:

22.987 to 23.000 mm (0.905 to 0.906 in.)

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

Standard idle gear inside diameter:

23.02 to 23.03 mm (0.906 to 0.907 in.)

(c) Subtract the idle gear shaft diameter measurement from the idle gear 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.)

(d) If the shaft oil clearance is more than the maximum, replace the idle gear shaft and idle gear.

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.

(b) If necessary, replace the No. 1 chain tensioner.

13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Check that the plunger moves smoothly.

(b) Measure the depth of wear of the chain tensioner.

Maximum depth:

1.0 mm (0.0394 in.)

(c) If the depth is more than the maximum, replace the No. 2 chain tensioner.

14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Check that the plunger moves smoothly.

(b) Measure the depth of wear of the chain tensioner.

Maximum depth:

1.0 mm (0.0394 in.)

(c) If the depth is more than the maximum, replace the No. 3 chain tensioner.

15. INSPECT CHAIN TENSIONER SLIPPER

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

Maximum depth:

1.0 mm (0.0394 in.)

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

16. 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.)

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

17. 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.)

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

18. INSPECT CAMSHAFT THRUST CLEARANCE

(a) Install the camshafts Reassembly.

(b) 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.)

(c) If the thrust clearance is more than the maximum, replace the camshafts.

If necessary, replace the camshaft bearing caps and cylinder head as a set.

19. INSPECT CAMSHAFT OIL CLEARANCE

(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.

(d) Install the camshaft bearing caps Reassembly.

NOTICE:
Do not turn the camshaft.

(e) Remove the camshaft bearing caps Disassembly.

(f) Measure the Plastigage at its widest point.

Standard Oil Clearance:

Maximum Oil Clearance:

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

20. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY

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

Maximum warpage:

0.70 mm (0.0276 in.)

(b) If the warpage is more than the maximum, replace the exhaust manifold.

21. INSPECT INTAKE MANIFOLD FOR FLATNESS

(a) Using a precision straightedge and feeler gauge, measure the warpage of the surfaces which contact the cylinder head and intake air surge tank.

Maximum Warpage:

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