Part 2

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

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.

28. INSPECT CONNECTING ROD THRUST CLEARANCE

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





Standard thrust clearance:

0.15 to 0.40 mm (0.0059 to 0.0157 in.)

Maximum thrust clearance:

0.50 mm (0.020 in.)

If the thrust clearance is greater than the maximum, replace the connecting rod assemblies. If necessary, replace the crankshaft.

29. INSPECT CONNECTING ROD OIL CLEARANCE

(a) Clean the crank pin and bearing.

(b) Check the crank pin and bearing for pitting and scratches.

(c) Lay a strip of Plastigage on the crank pin.





(d) Check that the front mark of the connecting rod cap is facing forward.





(e) Install the connecting rod cap Reassembly.

NOTICE:
Do not turn the crankshaft.

(f) Remove the 2 bolts and connecting rod cap Disassembly.

(g) Measure the Plastigage at its widest point.





Standard oil clearance:

0.045 to 0.067 mm (0.0018 to 0.0026 in.)

Maximum oil clearance
0.070 mm (0.0028 in.)

If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.

HINT
If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, 3 or 4 mark on its surface.

Connecting rod diameter:





Connecting rod bearing center wall thickness:





Crankshaft pin diameter:

52.992 to 53.000 mm (2.0863 to 2.0866 in.)

NOTICE:
Completely remove the Plastigage after the measurement.

30. INSPECT CRANKSHAFT THRUST CLEARANCE

(a) Install the crankshaft bearing cap Reassembly.

(b) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.





Standard thrust clearance:

0.04 to 0.24 mm (0.0016 to 0.0094 in.)

Maximum thrust clearance:

0.30 mm (0.0118 in.)

If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.

Thrust washer thickness:

2.43 to 2.48 mm (0.0957 to 0.0976 in.)

31. INSPECT 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:

0.07 mm (0.0028 in.)

If the warpage is greater than the maximum, replace the cylinder block.

(b) Visually check the cylinder for vertical scratches.





If deep scratches are present, rebore all the 6 cylinders. If necessary, replace the cylinder block.

32. 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:

94.200 mm (3.7087 in.)

If the diameter is greater than the maximum, replace the cylinder block.

33. INSPECT PISTON SUB-ASSEMBLY WITH PIN

(a) Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston end as specified.





Distance:

8.9 mm (0.3504 in.)

Standard diameter:

93.960 to 93.980 mm (3.6992 to 3.7000 in.)

Maximum diameter:

93.830 mm (3.6941 in.)

34. INSPECT PISTON OIL CLEARANCE

(a) Measure the cylinder bore diameter in the thrust direction.

(b) Subtract the piston diameter measurement from the cylinder bore diameter measurement.

Standard oil clearance:

0.020 to 0.052 mm (0.0008 to 0.0020 in.)

Maximum oil clearance:

0.060 mm (0.0024 in.)

If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.

35. 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:





If the clearance is not as specified, replace the piston.

36. INSPECT PISTON RING END GAP

(a) Insert the piston ring into the cylinder bore.





(b) 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.

(c) Using a feeler gauge, measure the end gap.





Standard end gap:





Maximum end gap:





If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum, even with a new piston ring, replace the cylinder block.

37. INSPECT PISTON PIN OIL CLEARANCE

(a) Using a caliper gauge, measure the inside diameter of the piston pin hole.





Piston pin hole inside diameter:





(b) Using a micrometer, measure the piston pin diameter.





Piston pin diameter:





(c) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement.

Standard oil clearance:

0.001 to 0.007 mm (0.00004 to 0.0003 in.)

Maximum oil clearance:

0.015 mm (0.0006 in.)

HINT
If the oil clearance is greater than the maximum, replace the piston and piston pin as a set.

(d) Using a caliper gauge, measure the inside diameter of the connecting rod bushing.





Bushing inside diameter:





(e) 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:

0.03 mm (0.0012 in.)

HINT
If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin as a set.

38. INSPECT CONNECTING ROD

(a) Using a rod aligner and feeler gauge, check the connecting rod alignment.





(1) Check for out-of-alignment.

Maximum out-of-alignment:

0.05 mm (0.0020 in.) per 100 mm (3.94 in.)

If the out-of-alignment is greater than the maximum, replace the connecting rod assembly.

(2) Check for 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.

39. REMOVE CONNECTING ROD SMALL END BUSH

(a) Using SST and a press, press out the bush.





SST : 09222-30010

40. INSPECT CONNECTING ROD BOLT

(a) Using a vernier caliper, measure the tension portion diameter 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.

41. INSPECT CRANKSHAFT

(a) Inspect for circle runout.





(1) Clean the crank journal.

(2) Place the crankshaft on the V-blocks.

(3) Using a dial indicator, measure the circle runout at the center journal.

Maximum circle runout:

0.06 mm (0.0024 in.)

If the circle runout is greater than the maximum, replace the crankshaft.

(b) Inspect the main journals.





(1) Using a micrometer, measure the diameter of each main journal.

Standard journal diameter:

60.988 to 61.00 mm (2.4011 to 2.4016 in.)

If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.

(2) Check each main journal for taper and out-of-round as shown in the illustration.

Maximum taper and out-of-round:

0.02 mm (0.0008 in.)

If the taper and out-of-round is greater than the maximum, replace the crankshaft.

(c) Inspect the crank pin.





(1) Using a micrometer, measure the diameter of each crank pin.

Diameter:

52.992 to 53.000 mm (2.0863 to 2.0866 in.)

If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.

(2) Check each crank pin for taper and out-of-round as shown in the illustration.

Maximum taper and out-of-round:

0.02 mm (0.0008 in.)

If the taper and out-of-round is greater than the maximum, replace the crankshaft.

42. INSPECT CRANKSHAFT OIL CLEARANCE

NOTICE:
Main bearings come in widths of 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

(a) Clean the main journal and the both surfaces of the bearing.





(b) Install the upper bearing.





(1) Install the upper bearing to the cylinder block as shown in the illustration.

NOTICE:
Do not apply engine oil to the bearing and its contact surface.

(c) Install the lower bearing.





(1) Install the lower bearing to the bearing cap.

(2) Using a vernier caliper, measure the distance between the bearing cap's edge and the lower bearing's edge.

Dimension (A - B):

0.7 mm (0.0276 in.) or less

NOTICE:
Do not apply engine oil to the bearing's contact area and underside.

(d) Place the crankshaft on the cylinder block.

(e) Lay a strip of Plastigage across each journal.





(f) Examine the front marks and numbers and install the bearing caps on the cylinder block.

HINT
A number is marked on each main bearing cap to indicate the installation position.

(g) Apply a light coat of engine oil to the threads and under the head of bearing cap bolts.

(h) Temporarily install the 8 main bearing cap bolts to the inside positions.

(i) Insert the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.





Bolt length:

100 to 102 mm (3.94 to 4.02 in.)

(j) Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.





(k) Apply a light coat of engine oil to the threads and under the head of the 8 main bearing cap bolts.

(l) Install the 8 main bearing cap bolts to the outside positions.





Bolt length:

105.5 to 107.5 mm (4.15 to 4.23 in.)

(m) Install and uniformly tighten the 16 main bearing cap bolts in several steps and in the sequence shown in the illustration.





Torque : 61 Nm (622 kgf-cm, 45 ft-lbf)

(n) Mark the front side of the bearing cap bolts with paint.





(o) Tighten the bearing cap bolts another 90° in the sequence shown in the illustration.

(p) Check that the painted mark is now at a 90° angle to the front.

NOTICE:
Do not turn the crankshaft.

(q) Install and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration.





Torque : 52 Nm (525 kgf-cm, 38 ft-lbf)

HINT
* Bolt (A) length: 45 mm (1.77 in.)
* Except bolt (A) length: 30 mm (1.18 in.)

(r) Remove the main bearing caps.

(s) Measure the Plastigage at its widest point.





Standard oil clearance:

0.026 to 0.047 mm (0.0010 to 0.0019 in.)

Maximum clearance:

0.050 mm (0.0020 in.)

If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

NOTICE:
Completely remove the Plastigage.

(t) If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.





Journal bearings:





HINT
EXAMPLE: Cylinder block "11" + Crankshaft "06" = Total number 17 (Use bearing "3")

Crankshaft main journal diameter:





Standard upper bearing center wall thickness (No. 1 and No. 4 journals):





Standard lower bearing center wall thickness (No. 1 and No. 4 journals):





Standard upper bearing center thickness (No. 2 and No. 3 journals):





Standard lower bearing center thickness (No. 2 and No. 3 journals):





43. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Using a vernier caliper, measure the minimum diameter of the compressed thread at the measuring point.





Standard diameter:

10.8 to 11.0 mm (0.4252 to 0.4331 in.)

Minimum diameter:

10.7 mm (0.4213 in.)

Measuring point:

40 mm (1.57 in.)

If the diameter is less than the minimum, replace the bolt.