2AR-FE ENGINE MECHANICAL ENGINE UNIT INSPECTION
PROCEDURE
13801
1.INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
Turn the roller by hand and check that it turns smoothly.
If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.
13750
2.INSPECT VALVE LASH ADJUSTER ASSEMBLY
- NOTICE:
- ·
Keep the adjuster free from dirt and foreign matter.
·Use only clean engine oil.
Place the lash adjuster into a container full of new engine oil.
| *1 | Taper Part | *2 | Plunger |
| *3 | Low Pressure Chamber | *4 | Check Ball |
| *5 | High Pressure Chamber | - | - |
| *a | CORRECT | *b | INCORRECT |
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
Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times.
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.
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.
3.INSPECT CAMSHAFT OIL CLEARANCE
- NOTICE:
-
Do not turn the camshafts.
Clean the bearing caps, camshaft housing and camshaft journals.
Place the camshafts on the camshaft housing.
| *1 | Plastigage |
Lay a strip of Plastigage across each of the camshaft journals.
Install the camshaft bearing caps.
Install the camshaft housing sub-assembly.
Remove the camshaft bearing caps.
| *1 | Plastigage |
| *2 | No. 1 Journal |
| *3 | Other Journals |
Measure the Plastigage at its widest point.
- Standard Oil Clearance:
Item Specified Condition Intake No. 1 journal 0.035 to 0.072 mm (0.00137 to 0.00283 in.) Exhaust No. 1 journal 0.049 to 0.086 mm (0.00193 to 0.00339 in.) Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.)
- Maximum Oil Clearance:
Item Specified Condition Intake No. 1 journal 0.085 mm (0.00335 in.) Exhaust No. 1 journal 0.095 mm (0.00374 in.) Other journals 0.085 mm (0.00335 in.)
If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the camshaft housing sub-assembly.
4.INSPECT CAMSHAFT THRUST CLEARANCE
13511
5.INSPECT CAMSHAFT
Inspect the camshaft runout.
Place the camshaft on V-blocks.
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.
- HINT:
-
Check the oil clearance after replacing the camshaft.
Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.
- Standard Cam Lobe Height:
Item Specified Condition Intake 44.163 to 44.305 mm (1.739 to 1.744 in.) Exhaust 44.144 to 44.286 mm (1.738 to 1.744 in.)
- Minimum Cam Lobe Height:
Item Specified Condition Intake 44.013 mm (1.733 in.) Exhaust 43.996 mm (1.732 in.)
If the cam lobe height is less than the minimum, replace the camshaft.
Inspect the camshaft journals.
Using a micrometer, measure the journal diameter.
- Standard Journal Diameter:
Item Specified Condition No. 1 journal 34.449 to 34.465 mm (1.356 to 1.357 in.) Other journals 22.959 to 22.975 mm (0.904 to 0.905 in.)
If the journal diameter is not as specified, check the oil clearance.
13050
6.INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
| *1 | Knock Pin Hole |
| *2 | Knock Pin |
Align the knock pin of the camshaft with the knock pin hole of the camshaft timing gear and attach the gear to the camshaft.
| *1 | Camshaft Timing Gear |
| *2 | Clearance |
| *3 | Camshaft Flange |
| *a | INCORRECT |
| *b | CORRECT |
| *c | No Clearance |
Check that there is no clearance between the camshaft timing gear and camshaft flange.
Fix the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.
- NOTICE:
-
Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.
Check the lock of the camshaft timing gear.
Make sure that the camshaft timing gear is locked.
- NOTICE:
-
Be careful not to damage the camshaft.
Release the lock pin.
Clean the camshaft journal with non-residue solvent.
Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
| *1 | Retard Side Path | *2 | Advance Side Path |
| *3 | Port A | *4 | Knock Pin |
| *a | Open | *b | Closed |
|
Rubber | 
|
Vinyl Tape |
- HINT:
-
There are 4 oil paths in the grooves of the camshaft. Plug three of the paths with pieces of rubber.
Open a hole at port A shown in the illustration.
While applying compressed air at approximately 200 kPa (2.0 kgf/ cm2, 29 psi) to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).
- CAUTION:
-
Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.
- NOTICE:
-
Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.
- HINT:
- ·
The camshaft timing gear assembly may be turned in the advance direction without applying any force.
·If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.
Check for smooth rotation.
Turn the camshaft timing gear within its movable range (26.5 to 28.5°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.
- NOTICE:
-
Do not allow the camshaft timing gear assembly to lock.
-
If it locks, release the lock pin again.
Remove the vinyl tape and pieces of rubber from the camshaft.
Remove the bolt and camshaft timing gear.
13070A
7.INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
| *1 | Knock Pin Hole |
| *2 | Knock Pin |
Align the knock pin of the No. 2 camshaft with the knock pin hole of the camshaft timing exhaust gear and attach the gear to the camshaft.
| *1 | Camshaft Timing Exhaust Gear |
| *2 | Clearance |
| *3 | Flange |
| *a | INCORRECT |
| *b | CORRECT |
| *c | No Clearance |
Check that there is no clearance between the camshaft timing exhaust gear and camshaft flange.
Fix the camshaft in place by hand, and then install the installation bolt of the camshaft timing exhaust gear by hand.
Check the lock of the camshaft timing exhaust gear.
Make sure that the camshaft timing exhaust gear is locked.
- NOTICE:
-
Be careful not to damage the camshaft.
Release the lock pin.
Clean the camshaft journal with non-residue solvent.
Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
| *1 | Advance Side Path | *2 | Retard Side Path |
| *3 | Knock Pin | - | - |
| *a | Open | *b | Closed |
|
|
Rubber |
|
Vinyl Tape |
- HINT:
-
There are 4 oil paths in the grooves of the camshaft. Plug 2 paths with pieces of rubber.
Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path as shown in the illustration.
| *1 | Retard Side Path |
| *2 | Advance Side Path |
Apply compressed air at approximately 200 kPa (2.0 kgf/cm2, 29 psi) to the two open paths (the advance side path and retard side path).
- NOTICE:
-
Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.
| *1 | Retard Side Path |
| *2 | Advance Side Path |
| *a | Hold Pressure |
| *b | Decompress |
Check that the camshaft timing exhaust gear turns 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 turns in the retard direction.
When the camshaft timing exhaust gear moves to the most retarded position, release the air pressure 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 may abruptly shift in the advance direction and break the lock pin or other parts.
Check for smooth rotation.
Turn the camshaft timing exhaust gear within its movable range (21.5 to 23.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.
- NOTICE:
-
When the air pressure is released from the advance side path and then from the retard side path, the gear 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.
Check the lock at the most advanced position.
Make sure that the camshaft timing exhaust gear locks at the most advanced position.
Remove the vinyl tape and pieces of rubber from the camshaft.
Remove the bolt and camshaft timing gear.
13506
8.INSPECT CHAIN SUB-ASSEMBLY
| *1 | Measuring Area |
Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.
Using a vernier caliper, measure the length of 15 pins.
- Maximum chain elongation:
137.7 mm (5.42 in.)
- HINT:
-
Perform the measurement at 3 random places.
If the elongation is more than the maximum, replace the chain sub-assembly.
13521
9.INSPECT CRANKSHAFT TIMING SPROCKET
Wrap the chain around the sprocket.
Using a vernier caliper, measure the sprocket diameter together with the chain.
- Minimum sprocket diameter (with chain):
59.94 mm (2.36 in.)
If the diameter is less than the minimum, replace the chain and crankshaft timing sprocket.
- HINT:
-
The vernier caliper must contact the chain rollers for the measurement.
13540
10.INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY
Move the stopper plate counterclockwise to release the lock. Push the plunger and check that it moves smoothly.
If necessary, replace the No. 1 chain tensioner assembly.
13559
11.INSPECT CHAIN TENSIONER SLIPPER
| *1 | Depth |
Measure the depth of wear of the chain tensioner slipper.
- Maximum depth:
1.0 mm (0.0394 in.)
If the depth is more than the maximum, replace the chain tensioner slipper.
13561
12.INSPECT NO. 1 CHAIN VIBRATION DAMPER
| *1 | Depth |
Measure the depth of wear of the chain vibration damper.
- Maximum depth:
1.0 mm (0.0394 in.)
If the depth is more than the maximum, replace the No. 1 chain vibration damper.
13566B
13.INSPECT TIMING CHAIN GUIDE
| *1 | Depth |
Measure the depth of wear of the timing chain guide.
- Maximum depth:
1.0 mm (0.0394 in.)
If the depth is more than the maximum, replace the timing chain guide.
14.INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.
- Standard thrust clearance:
0.05 to 0.09 mm (0.00197 to 0.00354 in.)
- Maximum thrust clearance:
0.09 mm (0.00354 in.)
If the thrust clearance is more than the maximum, replace the engine balancer assembly.
15.INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the No. 2 balance shaft back and forth.
- Standard thrust clearance:
0.05 to 0.09 mm (0.00197 to 0.00354 in.)
- Maximum thrust clearance:
0.09 mm (0.00354 in.)
If the thrust clearance is more than the maximum, replace the engine balancer assembly.
16.INSPECT BALANCE SHAFT BACKLASH
| *a | Fix in place |
Fix the No. 2 balance shaft in place, and then, using a dial indicator, measure the backlash of the No. 1 and No. 2 balance shafts as shown in the illustration.
- Standard backlash:
0.04 to 0.17 mm (0.00154 to 0.00669 in.)
- Maximum backlash:
0.17 mm (0.00669 in.)
- NOTICE:
-
Measure at 3 or more areas around the circumference of the No. 1 and No. 2 balance shafts.
If the backlash is more than the maximum, replace the engine balancer assembly.
11101A
17.INSPECT CYLINDER HEAD BOLT
| *1 | Measuring Point |
Using a vernier caliper, measure the diameter of the elongated thread at the measuring point.
- Measuring point:
106 mm (4.17 in.)
- Standard diameter:
10.85 to 11.00 mm (0.427 to 0.433 in.)
- Minimum diameter:
10.6 mm (0.417 in.)
If the diameter is less than the minimum, replace the cylinder head bolt.
- HINT:
-
If a visual check reveals no excessively thin areas, check the center of the bolt (see illustration) and find the area that has the smallest diameter.
25051
18.INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
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 converter sub-assembly.
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