Engine Unit
2TR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION
1. INSPECT CHAIN SUB-ASSEMBLY
(a) Pull the chain with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.
(b) Using a vernier caliper, measure the length of 16 links.
Maximum chain elongation:
147.5 mm (5.81 in.)
Text in Illustration
NOTICE:
Perform the measurement at 3 random places.
If the elongation is more than the maximum, replace the chain.
2. INSPECT NO. 2 CHAIN SUB-ASSEMBLY
(a) Pull the chain with a force of 147 N (15 kgf, 33.0 lbf).
(b) Using a vernier caliper, measure the length of 16 links.
Maximum chain elongation:
123.6 mm (4.87 in.)
NOTICE:
Perform the measurement at 3 random places.
If the elongation is more than the maximum, replace the chain.
3. 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
4. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Move the stopper plate downward to release the lock. Push the plunger and check that it moves smoothly.
Text in Illustration
5. INSPECT CAMSHAFT TIMING SPROCKET
(a) Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip.
Minimum distance:
1.0 mm (0.0394 in.)
Text in Illustration
If the distance is less than the minimum, replace the sprocket.
If the worn area is too small or difficult to distinguish from a normal area, perform the following 2 steps.
(b) Wrap the chain around the sprocket.
(c) Using a vernier caliper, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain):
113.8 mm (4.48 in.)
HINT
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the chain and sprocket.
6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Measure the distance between the most worn out timing gear tip and the beginning of the worn area below the tip.
Minimum distance:
1.0 mm (0.0394 in.)
Text in Illustration
If the distance is less than the minimum, replace the timing gear.
If the worn area is too small or difficult to distinguish from a normal area, perform the following 2 steps.
(b) Wrap the chain around the timing gear.
(c) Using a vernier caliper, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain):
113.8 mm (4.48 in.)
HINT
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the chain and timing gear.
7. INSPECT CRANKSHAFT TIMING GEAR
(a) Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip.
Minimum distance:
1.0 mm (0.0394 in.)
Text in Illustration
If the distance is less than the minimum, replace the sprocket.
If the worn area is too small or difficult to distinguish from a normal area, perform the following 2 steps.
(b) Wrap the chain around the drive sprocket.
(c) Using a vernier caliper, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain):
59.4 mm (2.34 in.)
HINT
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the chain and sprocket.
8. INSPECT CHAIN TENSIONER SLIPPER
(a) Using a vernier caliper, measure the tensioner slipper depth.
Maximum depth:
2.0 mm (0.0787 in.)
Text in Illustration
If the depth is more than the maximum, replace the tensioner slipper.
9. INSPECT NO. 1 CHAIN VIBRATION DAMPER
(a) Using a vernier caliper, measure the vibration damper depth.
Maximum depth:
2.0 mm (0.0787 in.)
Text in Illustration
If the depth is more than the maximum, replace the vibration damper.
10. INSPECT TIMING CHAIN GUIDE
(a) Using a vernier caliper, measure the chain guide depth.
Maximum depth:
0.5 mm (0.0197 in.)
Text in Illustration
If the depth is more than the maximum, replace the timing chain guide.
11. INSPECT NO. 2 CRANKSHAFT TIMING SPROCKET
(a) Wrap the chain around the sprocket.
(b) Using a vernier caliper, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain):
96.7 mm (3.81 in.)
HINT
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the chain and sprocket.
12. INSPECT BALANCE SHAFT DRIVE GEAR SUB-ASSEMBLY
(a) Wrap the chain around the sprocket.
(b) Using a vernier caliper, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain):
75.9 mm (2.99 in.)
HINT
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the chain and sprocket.
13. INSPECT NO. 2 CHAIN VIBRATION DAMPER
(a) Using a vernier caliper, measure the vibration damper depth.
Maximum depth:
1.0 mm (0.0394 in.)
Text in Illustration
If the depth is more than the maximum, replace the vibration damper.
14. INSPECT NO. 3 CHAIN VIBRATION DAMPER
(a) Using a vernier caliper, measure the vibration damper depth.
Maximum depth:
1.0 mm (0.0394 in.)
Text in Illustration
If the depth is more than the maximum, replace the vibration damper.
15. INSPECT NO. 4 CHAIN VIBRATION DAMPER
(a) Using a vernier caliper, measure the vibration damper depth.
Maximum depth:
1.0 mm (0.0394 in.)
Text in Illustration
If the depth is more than the maximum, replace the vibration damper.
16. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier caliper, measure the diameter of the most elongated threads in the measuring area.
Standard outside diameter:
10.76 to 10.97 mm (0.424 to 0.432 in.)
Minimum outside diameter:
10.40 mm (0.409 in.)
Distance:
30 mm (1.18 in.)
Text in Illustration
If a visual check reveals no excessively thin areas, check the center of the measuring area (see illustration) and find the area that has the smallest diameter.
If the diameter is less than the minimum, replace the cylinder head bolt.
17. 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.
18. INSPECT CAMSHAFT
(a) Check the camshaft runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout:
0.03 mm (0.00118 in.)
If the circle runout is more than the maximum, replace the camshaft.
(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
42.855 to 42.955 mm (1.687 to 1.691 in.)
Minimum cam lobe height:
42.855 mm (1.687 in.)
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.
19. INSPECT NO. 2 CAMSHAFT
(a) Check the camshaft runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout:
0.03 mm (0.00118 in.)
If the circle runout is more than the maximum, replace the camshaft.
(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
42.854 to 42.954 mm (1.687 to 1.691 in.)
Minimum cam lobe height:
42.854 mm (1.687 in.)
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.
20. INSPECT CAMSHAFT THRUST CLEARANCE Testing and Inspection
21. INSPECT CAMSHAFT OIL CLEARANCE Testing and Inspection
22. INSPECT EXHAUST MANIFOLD
(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.)
If the warpage is more than the maximum, replace the exhaust manifold.