7GR-FKS ENGINE MECHANICAL ENGINE UNIT INSPECTION
PROCEDURE
13801
1.INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
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.
13750
2.INSPECT VALVE LASH ADJUSTER ASSEMBLY
- NOTICE:
- ·
Keep the valve lash adjuster assembly free of dirt and foreign objects.
·Only use clean engine oil.
Place the valve lash adjuster assembly into a container filled with engine oil.
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
| *a | CORRECT | *b | INCORRECT |
| *c | Tapered Path | *d | Plunger |
| *e | Low Pressure Chamber | *f | Check Ball |
| *g | High Pressure Chamber | - | - |
Squeeze SST and the valve lash adjuster assembly 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 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.
After bleeding 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 assembly with a new one.
13511
3.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.)
- HINT:
- ·
If the runout is more than the maximum, replace the camshaft.
·Check the oil clearance after replacing the camshaft.
Using a micrometer, measure the cam lobe height.
- Standard Cam Lobe Height:
Item Specified Condition Intake camshaft for Bank 1 44.3229 to 44.4229 mm (1.74499 to 1.74893 in.) for Bank 2 44.3221 to 44.4221 mm (1.74496 to 1.74890 in.) Exhaust camshaft for Bank 1 44.4377 to 44.5377 mm (1.74951 to 1.75345 in.) for Bank 2 44.4356 to 44.5356 mm (1.74943 to 1.75337 in.)
- Minimum Cam Lobe Height:
Item Specified Condition Intake camshaft for Bank 1 37.95 mm (1.49409 in.) for Bank 2 37.95 mm (1.49409 in.) Exhaust camshaft for Bank 1 37.95 mm (1.49409 in.) for Bank 2 37.95 mm (1.49409 in.)
- HINT:
-
If the cam lobe height is less than the minimum, replace the camshaft.
Using a micrometer, measure the journal diameter.
- Standard Journal Diameter:
Item Specification No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.) No. 2, 3, 4 Journal 25.959 to 25.975 mm (1.0220 to 1.0226 in.) No. 5 Journal 25.969 to 25.985 mm (1.0223 to 1.0230 in.)
- HINT:
-
If the journal diameter is not as specified, check the oil clearance.
11101A
4.INSPECT CYLINDER HEAD SET BOLT
| *a | Measurement Point |
| *b | 100 mm |
Using a vernier caliper, measure the diameter of the threads at the measurement point.
- Standard Diameter:
10.85 to 11.00 mm (0.427 to 0.433 in.)
- Minimum Diameter:
10.70 mm (0.421 in.)
- Measurement Point (Distance from the Seat):
100 mm (3.94 in.)
- HINT:
- ·
If the diameter is less than the minimum, replace the cylinder head set bolt. Failure to do so may lead to engine damage.
·If there is any thread deformation, replace the cylinder head set bolt with a new one.
13506
5.INSPECT CHAIN SUB-ASSEMBLY
| *a | Measurement Area |
Using a spring scale, pull the chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) and measure the length of the chain using a vernier caliper.
- Maximum chain elongation:
136.7 mm (5.38 in.)
- HINT:
-
Perform the measurement at 3 random places. If a measurement is more than the maximum, replace the chain sub-assembly.
13507
6.INSPECT NO. 2 CHAIN SUB-ASSEMBLY
| *a | Measurement Area |
Using a spring scale, pull the No. 2 chain sub-assembly 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. If a measurement is more than the maximum, replace the No. 2 chain sub-assembly.
13521
7.INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
Place the chain sub-assembly around the crankshaft timing gear or sprocket.
Using a vernier caliper, measure the diameter of the crankshaft timing gear or sprocket with the chain sub-assembly.
- Maximum Sprocket Diameter (with Chain Sub-assembly):
61.4 mm (2.42 in.)
- HINT:
- ·
The vernier caliper must contact the chain rollers when measuring.
·If the diameter is more than the maximum, replace the chain sub-assembly and crankshaft timing gear or sprocket.
13530
8.INSPECT IDLE SPROCKET ASSEMBLY
Place the chain sub-assembly around the idle sprocket assembly.
Using a vernier caliper, measure the diameter of the idle sprocket assembly with the chain sub-assembly.
- Maximum Sprocket Diameter (with Chain Sub-assembly):
61.4 mm (2.42 in.)
- HINT:
- ·
The vernier caliper must contact the chain rollers when measuring.
·If the diameter is more than the maximum, replace the chain sub-assembly and idle sprocket assembly.
9.INSPECT IDLE GEAR SHAFT OIL CLEARANCE
Using a micrometer, measure the idle gear shaft diameter.
- Standard idle gear shaft diameter:
22.987 to 23.000 mm (0.905 to 0.906 in.)
Using a caliper gauge, measure the inside diameter of the idle gear.
- Standard idle gear inside diameter:
23.020 to 23.030 mm (0.906 to 0.907 in.)
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.)
- HINT:
-
If the oil clearance is more than the maximum, replace the No. 1 idle gear shaft and idle sprocket assembly.
13540
10.INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY
| *a | Plunger |
| *b | Stopper Plate |
Turn the stopper plate clockwise to release the lock. Push the plunger and check that it moves smoothly.
- HINT:
-
If the plunger does not move smoothly, replace the No. 1 chain tensioner assembly.
13550
11.INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
| *a | Depth |
Check that the plunger moves smoothly.
Using a vernier caliper, measure the wear depth of the No. 2 chain tensioner assembly.
- Maximum Depth:
0.9 mm (0.0354 in.)
- HINT:
-
If the depth is more than the maximum, replace the No. 2 chain tensioner assembly.
13560A
12.INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY
| *a | Depth |
Check that the plunger moves smoothly.
Using a vernier caliper, measure the wear depth of the No. 3 chain tensioner assembly.
- Maximum Depth:
0.9 mm (0.0354 in.)
- HINT:
-
If the depth is more than the maximum, replace the No. 3 chain tensioner assembly.
13559
13.INSPECT CHAIN TENSIONER SLIPPER
| *a | Depth |
Measure the depth of wear of the chain tensioner slipper.
- Maximum depth:
1.0 mm (0.0394 in.)
- HINT:
-
If the depth is more than the maximum, replace the chain tensioner slipper.
13561
14.INSPECT NO. 1 CHAIN VIBRATION DAMPER
| *a | Depth |
Measure the depth of wear of the No. 1 chain vibration damper.
- Maximum depth:
1.0 mm (0.0394 in.)
- HINT:
-
If the depth is more than the maximum, replace the No. 1 chain vibration damper.
13562
15.INSPECT NO. 2 CHAIN VIBRATION DAMPER
| *a | Depth |
Using a vernier caliper, measure the wear depth of the No. 2 chain vibration damper.
- Maximum Depth:
1.0 mm (0.0394 in.)
- HINT:
-
If the depth is more than the maximum, replace the No. 2 chain vibration damper.
16.INSPECT CAMSHAFT OIL CLEARANCE
for Bank 1:
Clean the camshaft bearing caps, camshaft housing and camshaft journals.
Place the camshafts on the camshaft housing.
| *a | Plastigage |
Lay a strip of Plastigage across each camshaft journal.
Install the camshaft bearing caps.
- NOTICE:
-
Do not turn the camshaft.
Remove the camshaft bearing caps.
| *a | Plastigage |
| *b | No. 1 Journal |
| *c | No. 2 Journal |
| *d | No. 3 Journal |
| *e | No. 4 Journal |
| *f | No. 5 Journal |
Measure the Plastigage at its widest point.
- Standard Oil Clearance:
Item Specified Condition No. 1 journal 0.032 to 0.063 mm (0.00126 to 0.00248 in.) No. 2, 3, 4 journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.) No. 5 journal 0.015 to 0.052 mm (0.000591 to 0.00205 in.)
- Maximum Oil Clearance:
Item Specified Condition No. 1 journal 0.10 mm (0.00394 in.) No. 2, 3, 4 journals 0.10 mm (0.00394 in.) No. 5 journal 0.10 mm (0.00394 in.)
If the oil clearance is more than the maximum, inspect the inner compression spring. If necessary, replace the camshaft. If the oil clearance is still more than the maximum after replacing the camshaft, replace the camshaft housing.
for Bank 2:
Clean the camshaft bearing caps, camshaft housing and camshaft journals.
Place the camshafts on the camshaft housing.
| *a | Plastigage |
Lay a strip of Plastigage across each camshaft journal.
Install the camshaft bearing caps.
- NOTICE:
-
Do not turn the camshaft.
Remove the camshaft bearing caps.
| *a | Plastigage |
| *b | No. 1 Journal |
| *c | Other Journals |
Measure the Plastigage at its widest point.
- Standard Oil Clearance:
Item Specified Condition No. 1 journal 0.032 to 0.063 mm (0.00126 to 0.00248 in.) Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
- Maximum Oil Clearance:
Item Specified Condition No. 1 journal 0.10 mm (0.00394 in.) Other journals 0.10 mm (0.00394 in.)
If the oil clearance is more than the maximum, inspect the inner compression spring. If necessary, replace the camshaft. If the oil clearance is still more than the maximum after replacing the camshaft, replace the camshaft housing.
17150
17.INSPECT EXHAUST MANIFOLD ASSEMBLY
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.)
If the warpage is more than the maximum, replace the exhaust manifold assembly.
17111
18.INSPECT INTAKE MANIFOLD
| *a | Intake Air Surge Tank Side |
| *b | Cylinder Head Side |
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:
0.10 mm (0.00394 in.)
If the warpage is more than the maximum, replace the intake manifold.