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EM–1242GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(i) 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 journal)
Standard lower bearing center wall thickness
(No. 1 and No. 4 journal)
A125230E02
Cylinder
block +
Crankshaft0 - 5 6 - 11 12 - 17 18 - 23 24 - 28
Bearing to
be used"1" "2" "3" "4" "5"
Mark Diameter
"00" 60.999 to 61.000 mm (2.4015 to 2.4016 in.)
"01" 60.998 to 60.999 mm (2.4015 to 2.4015 in.)
"02" 60.997 to 60.998 mm (2.4015 to 2.4015 in.)
"03" 60.996 to 60.997 mm (2.4014 to 2.4015 in.)
"04" 60.995 to 60.996 mm (2.4014 to 2.4014 in.)
"05" 60.994 to 60.995 mm (2.4013 to 2.4014 in.)
"06" 60.993 to 60.994 mm (2.4013 to 2.4013 in.)
"07" 60.992 to 60.993 mm (2.4013 to 2.4013 in.)
"08" 60.991 to 60.992 mm (2.4012 to 2.4013 in.)
"09" 60.990 to 60.991 mm (2.4012 to 2.4012 in.)
"10" 60.989 to 60.990 mm (2.4011 to 2.4012 in.)
"11" 60.988 to 60.989 mm (2.4011 to 2.4011 in.)
Mark Thickness
"1" 2.500 to 2.503 mm (0.0984 to 0.0985 in.)
"2" 2.503 to 2.506 mm (0.0985 to 0.0987 in.)
"3" 2.506 to 2.509 mm (0.0987 to 0.0988 in.)
"4" 2.509 to 2.512 mm (0.0988 to 0.0989 in.)
"5" 2.512 to 2.515 mm (0.0989 to 0.0990 in.)
Mark Thickness
"1" 2.478 to 2.481 mm (0.0976 to 0.0977 in.)
"2" 2.481 to 2.484 mm (0.0977 to 0.0978 in.)
"3" 2.484 to 2.487 mm (0.0978 to 0.0979 in.)
"4" 2.487 to 2.490 mm (0.0979 to 0.0980 in.)
"5" 2.490 to 2.493 mm (0.0980 to 0.0981 in.)
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2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–125
EM
Standard upper bearing center wall thickness
(No. 2 and No. 3 journal)
Standard lower bearing center wall thickness
(No. 2 and No. 3 journal)
43. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using vernier calipers, 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.
Mark Thickness
"1" 2.478 to 2.481 mm (0.0976 to 0.0977 in.)
"2" 2.481 to 2.484 mm (0.0977 to 0.0978 in.)
"3" 2.484 to 2.487 mm (0.0978 to 0.0979 in.)
"4" 2.487 to 2.490 mm (0.0979 to 0.0980 in.)
"5" 2.490 to 2.493 mm (0.0980 to 0.0981 in.)
Mark Thickness
"1" 2.500 to 2.503 mm (0.0984 to 0.0985 in.)
"2" 2.503 to 2.506 mm (0.0985 to 0.0987 in.)
"3" 2.506 to 2.509 mm (0.0987 to 0.0988 in.)
"4" 2.509 to 2.512 mm (0.0988 to 0.0989 in.)
"5" 2.512 to 2.515 mm (0.0989 to 0.0990 in.)
A125160E02
Page 931 of 3000

2GR-FE ENGINE MECHANICAL – ENGINEEM–1
EM
ENGINE
ON-VEHICLE INSPECTION
1. INSPECT ENGINE COOLANT
(a) Inspect the engine coolant (See page CO-1).
2. INSPECT ENGINE OIL
(a) Inspect the engine oil (See page LU-1).
3. INSPECT BATTERY
(a) Inspect the battery (See page CH-5).
4. INSPECT AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
(a) Remove the air cleaner filter element sub-assembly.
(b) Visually check that there is no dirt, blockage, and/or
damage to the air cleaner filter element.
HINT:
• If there is any dirt or a blockage in the air cleaner
filter element, clean it with compressed air.
• If any dirt or a blockage remains even after
cleaning the air cleaner filter element with
compressed air, replace it.
5. INSPECT SPARK PLUG
(a) Inspect the spark plugs (See page IG-5).
6. INSPECT VALVE LASH ADJUSTER NOISE
(a) Rev up the engine several times. Check that the
engine does not emit unusual noises.
If unusual noises occur, warm up the engine and
idle it for over 30 minutes. Then repeat this
procedure.
HINT:
If any defects or problems are found during the
inspection above, perform lash adjuster inspection
(See page EM-100).
7. INSPECT IGNITION TIMING
(a) Warm up the engine.
(b) When using the intelligent tester:
Check the ignition timing.
(1) Connect the intelligent tester to the DLC3.
(2) Enter DATA LIST mode with the intelligent
tester.
Ignition timing:
8 to 12
BTDC at idle
HINT:
Refer to the intelligent tester operator's manual
for help when selecting the DATA LIST.
C110200E02
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EM–22GR-FE ENGINE MECHANICAL – ENGINE
EM
(c) When not using the intelligent tester:
Check the ignition timing.
(1) Using SST, connect terminals 13 (TC) and 4
(CG) of the DLC3.
SST 09843-18040
NOTICE:
• Confirm the terminal numbers before
connecting them. Connection with a
wrong terminal can damage the engine.
• Turn off all electrical systems before
connecting the terminals.
• Perform this inspection after the cooling
fan motor is turned off.
(2) Remove the V-bank cover.
(3) Pull out the red lead wire harness.
(4) Connect the tester terminal of the timing light to
the red lead wire as shown in the illustration.
NOTICE:
Use a timing light which can detect the first
signal.
(5) Check the ignition timing at idle.
Ignition timing:
8 to 12
BTDC at idle
NOTICE:
When checking the ignition timing, the
transmission should be in neutral.
HINT:
Run the engine at 1000 to 1300 rpm for 5
seconds, and then check that the engine rpm
returns to idle speed.
(6) Disconnect terminals 13 (TC) and 4 (CG) of the
DLC3.
(7) Check the ignition timing at idle.
Ignition timing:
7 to 24
BTDC at idle
(8) Confirm that the ignition timing moves to the
advanced angle side when the engine rpm is
increased.
(9) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up the engine.
(b) When using the intelligent tester:
Check the idle speed.
(1) Connect the intelligent tester to the DLC3.
(2) Enter DATA LIST mode with the intelligent
tester.
Idle speed:
600 to 700 rpm
NOTICE:
• When checking the idle speed, the
transmission should be in neutral.
• Check the idle speed with the cooling fan
off.
A122830E14
A132997
C110200E02
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2GR-FE ENGINE MECHANICAL – ENGINEEM–3
EM
• Switch off all accessories and air
conditioning before connecting the
intelligent tester.
HINT:
Refer to the intelligent tester operator's manual
for further details.
(c) When not using the intelligent tester:
Check the idle speed.
(1) Using SST, connect the tachometer test probe
to terminal 9 (TAC) of the DLC3.
SST 09843-18030
(2) Check the idle speed.
Idle speed:
600 to 700 rpm
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the intake air surge tank (See page ES-
521).
(d) Remove the 6 ignition coils.
(e) Remove the 6 spark plugs.
(f) Check the cylinder compression pressure.
(1) Insert a compression gauge into the spark plug
hole.
(2) While cranking the engine, measure the
compression pressure.
Compression pressure:
1.3 MPa (13 kgf/cm
2, 189 psi)
Minimum pressure:
0.98 MPa (10 kgf/cm
2, 142 psi)
Difference between each cylinder:
0.1 MPa (1.0 kgf/cm
2, 15 psi)
NOTICE:
• Always use a fully charged battery to
obtain an engine speed of 250 rpm or
more.
• Check the other cylinders' compression
pressure in the same way.
• This measurement must be done as
quickly as possible.
(3) If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through
the spark plug hole and inspect again.
HINT:
• If adding oil increases the compression, the
piston rings and/or cylinder bore may be
worn or damaged.
• If pressure stays low, a valve may be stuck
or seated improperly, or there may be
leakage in the gasket.
(g) Install the 6 spark plugs.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
A122830E15
A129621
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EM–42GR-FE ENGINE MECHANICAL – ENGINE
EM
(h) Install the 6 ignition coils.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(i) Install the intake air surge tank (See page ES-522).
10. INSPECT CO/HC
(a) Start the engine.
(b) Run the engine at 2500 rpm for approximately 180
seconds.
(c) Insert the CO/HC meter testing probe at least 40 cm
(1.3 ft.) into the tailpipe during idling.
(d) Check CO/HC concentration at idle and/or 2500
rpm.
HINT:
Check regulations and restrictions in your area
when performing 2 mode CO/HC concentration
testing (engine check at both idle speed and at 2500
rpm).
If the CO/HC concentration does not comply with
regulations, perform troubleshooting in the order
given below.
(1) Check air fuel ratio sensor and heated oxygen
sensor operation.
(2) See the table below for possible causes, and
then inspect and repair.
CO HC Problems Causes
Normal High Rough idle1. Faulty ignitions:
– Incorrect timing
– Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaks in intake and exhaust valves
4. Leaks in cylinders
Low HighRough idle
(fluctuating HC reading)1. Vacuum leaks:
– PCV hoses
– Intake manifold
– Throttle body
– Brake booster line
2. Lean mixture causing misfire
High HighRough idle
(black smoke from exhaust)1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI system:
– Faulty fuel pressure regulator
– Defective ECT sensor
– Defective MAF meter
–Faulty ECM
– Faulty injectors
– Faulty throttle position sensor
Page 935 of 3000
EM–1262GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
REASSEMBLY
1. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, tap in new straight pins to
the cylinder block.
Standard protrusion
A131842E02
Item Protrusion
Pin A 23 mm (0.906 in.)
Pin B 6 mm (0.236 in.)
Pin C 11 mm (0.433 in.)
Page 936 of 3000
2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–127
EM
2. INSTALL STUD BOLT
(a) Using E8 and E10 "TORX" sockets, install the stud
bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A
17 N*m (173 kgf*cm, 13 ft.*lbf) for bolt B
3. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, install the No. 1 oil
nozzle sub-assembly.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
4. INSTALL PISTON SUB-ASSEMBLY WITH PIN
(a) Using a screwdriver, install a new piston pin hole
snap ring at one end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not
aligned with the pin hole cutout portion of the piston.
Pin D 9 mm (0.354 in.)Item Protrusion
A134958E01
A120734
A131876E01