Part 2

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

10. INSPECT IDLE GEAR SHAFT OIL CLEARANCE

(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.)

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





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 (0.0008 to 0.0017 in.)

Maximum oil clearance:

0.093 mm (0.0037 in.)

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

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. If necessary, replace the No. 1 chain tensioner assembly.





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 worn depth of the No. 2 chain tensioner.

Maximum depth:

0.9 mm (0.035 in.)

If the depth is greater 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 worn depth of the No. 3 chain tensioner.

Maximum depth:

0.9 mm (0.035 in.)

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

14. INSPECT CHAIN TENSIONER SLIPPER

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





Maximum depth:

1.0 mm (0.039 in.)

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

15. INSPECT NO. 1 CHAIN VIBRATION DAMPER

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





Maximum depth:

1.0 mm (0.039 in.)

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

16. INSPECT NO. 2 CHAIN VIBRATION DAMPER

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





Maximum depth:

1.0 mm (0.039 in.)

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

17. INSPECT CYLINDER HEAD SUB-ASSEMBLY

(a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder block and manifolds.





Standard warpage:





Maximum warpage:

0.10 mm (0.0039 in.)

If the warpage is greater than the maximum, replace the cylinder head assembly.

(b) Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head assembly.





18. INSPECT INTAKE VALVE

(a) Using a micrometer, measure the diameter of the valve stem.





Valve stem diameter:

5.470 to 5.485 mm (0.2154 to 0.2159 in.)

If the valve stem is not as specified, check the oil clearance.

(b) Using a vernier caliper, measure the valve head margin thickness.





Standard margin thickness:

1.0 mm (0.0394 in.)

Minimum margin thickness:

0.5 mm (0.0197 in.)

If the margin thickness is less than the minimum, replace the intake valve.

(c) Using a vernier caliper, measure the valve's overall length.





Standard overall length:

105.85 mm (4.1673 in.)

Minimum overall length:

105.35 mm (4.1476 in.)

If the overall length is less than the minimum, replace the intake valve.

19. INSPECT EXHAUST VALVE

(a) Using a micrometer, measure the diameter of the valve stem.





Valve stem diameter:

5.465 to 5.480 mm (0.2151 to 0.2157 in.)

If the valve stem is not as specified, check the oil clearance.

(b) Using a vernier caliper, measure the valve head margin thickness.





Standard margin thickness:

1.0 mm (0.0394 in.)

Minimum margin thickness:

0.5 mm (0.0197 in.)

If the margin thickness is less than the minimum, replace the exhaust valve.

(c) Using a vernier caliper measure the valve's overall length.





Standard overall length:

110.40 mm (4.3464 in.)

Minimum overall length:

109.90 mm (4.3268 in.)

If the overall length is less than the minimum, replace the exhaust valve.

20. INSPECT INTAKE VALVE SEATS

(a) Apply a light coat of prussian blue to the valve face.






(b) Lightly press the valve face against the valve seat.

(c) Check the valve face and valve seat by using the following procedure.

(1) If prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.

(2) If prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat.

(3) Check that the valve seat contacts in the middle of the valve face with the width between 1.1 and 1.6 mm (0.043 and 0.063 in.).

21. INSPECT EXHAUST VALVE SEATS

(a) Apply a light coat of prussian blue to the valve face.





(b) Lightly press the valve face against the valve seat.

(c) Check the valve face and valve seat by using the following procedure.

(1) If prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.

(2) If prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat.

(3) Check that the valve seat contacts in the middle of the valve face with the width between 1.1 and 1.6 mm (0.043 and 0.063 in.).

22. REPAIR INTAKE VALVE SEATS

NOTICE:
Keep the lip free from foreign matter.

(a) If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.





(b) If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.





(c) Handrub the valve and valve seat with an abrasive compound.

(d) Check the valve seating position.

23. REPAIR EXHAUST VALVE SEATS

NOTICE:
Keep the lip free from foreign matter.

(a) If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.





(b) If the seating is too low on the valve face, use 45° and 75° cutters to correct the seat.





(c) Handrub the valve and valve seat with an abrasive compound.

(d) Check the valve seating position.

24. INSPECT INNER COMPRESSION SPRING

(a) Using a vernier caliper, measure the free length of the inner compression spring.





Free length:

45.91 mm (1.8075 in.)

If the free length is not as specified, replace the spring.

(b) Using a steel square, measure the deviation of the inner compression spring.





Maximum deviation:

1.0 mm (0.039 in.)

Maximum angle (reference):

2°

If the deviation is greater than the maximum, replace the spring.

25. INSPECT VALVE GUIDE BUSH OIL CLEARANCE

(a) Using a caliper gauge, measure the inside diameter of the valve guide bush.





Bush inside diameter:

5.510 to 5.530 mm (0.2169 to 0.2177 in.)

(b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.

Standard clearance:





Maximum oil clearance:





For intake side:

If the clearance is greater than the maximum, replace the intake valve and intake valve guide bush.

For exhaust side:

If the clearance is greater than the maximum, replace the exhaust valve and exhaust valve guide bush.

26. INSPECT CAMSHAFT THRUST CLEARANCE

(a) Install the bank 1 camshaft 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 (0.0031 to 0.0051 in.)

Maximum thrust clearance:

0.15 mm (0.006 in.)

If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

(c) Install the bank 2 camshaft Reassembly.

(d) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

Standard thrust clearance:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

Maximum thrust clearance:

0.15 mm (0.006 in.)

If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

27. 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 of the camshaft journals.

(d) Install the bearing caps Reassembly.

NOTICE:
Do not turn the camshaft.

(e) Remove the bearing caps Disassembly.

(f) Measure the Plastigage at its widest point.





Standard oil clearance:





Maximum oil clearance:





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

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

(h) Place the camshafts on the camshaft housing.

(i) Lay a strip of Plastigage across each of the camshaft journals.





(j) Install the bearing caps Reassembly.

NOTICE:
Do not turn the camshaft.

(k) Remove the bearing caps Disassembly.

(l) Measure the Plastigage at its widest point.





Standard oil clearance:





Maximum oil clearance:





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