Page 1049 of 3000

EM–1022GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(c) Using a micrometer, measure the journal diameter.
Standard journal diameter
If the journal diameter is not as specified, check the
oil clearance.
4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Clamp the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft in the
vise.
(b) Put the camshaft timing gear assembly and
camshaft together by aligning the key groove and
straight pin.
(c) Lightly press the camshaft timing gear assembly
against the camshaft, and turn the camshaft timing
gear assembly. Push further at the position where
the pin enters the groove.
NOTICE:
Be sure not to turn the camshaft timing gear in
the retard direction (the right angle).
(d) Check that there is no clearance between the
camshaft timing gear assembly's flange and the
camshaft.
(e) Tighten the flange bolt with the camshaft timing gear
fixed.
Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
(f) Check the lock of the camshaft timing gear
assembly.
(1) Clamp the camshaft in a vise, and confirm that
the camshaft timing gear assembly is locked.
NOTICE:
Be careful not to damage the camshaft.
A109633
Item Specification
No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.)
A109635E02
A109634
Page 1050 of 3000

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–103
EM
(g) Release the lock pin.
(1) Cover the 4 oil paths of the cam journal with
vinyl tape as shown in the illustration.
HINT:
2 advance side paths are provided in the
groove of the camshaft. Plug one of the paths
with a rubber piece.
(2) Break through the tape of the advance side
path and the retard side path on the opposite
side to the hole of the advance side path, as
shown in the illustration.
(3) Apply approximately 200 kPa (2.0 kgf/cm
2, 28
psi) of air pressure to the 2 broken paths.
CAUTION:
Cover the paths with a piece of cloth when
applying pressure to keep oil from
splashing.
(4) Check that the camshaft timing gear assembly
revolves in the advance direction when
reducing the air pressure applied to the retard
side path.
HINT:
This operation releases the lock pin for the
most retarded position.
(5) When the camshaft timing gear assembly
reaches the most advanced position, release
the air pressure from the retard side path and
advance side path, in that order.
NOTICE:
Do not release the air pressure from the
advance side path first. The gear may
abruptly shift in the retard direction and
break the lock pin.
A106100E02
A106101E03
A106102E02
Page 1051 of 3000

EM–1042GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(h) Check for smooth rotation.
(1) Turn the camshaft timing gear assembly within
its movable range (21
) 2 or 3 times, but do not
turn it to the most retarded position. Make sure
that the gear turns smoothly.
NOTICE:
Do not use air pressure to perform the
smooth operation check.
(i) Check the lock in the most retarded position.
(1) Confirm that the camshaft timing gear
assembly is locked at the most retarded
position.
(j) Remove the flange bolt and camshaft timing gear
assembly.
NOTICE:
• Do not remove the other 3 bolts.
• If planning to reuse the gear, be sure to
release the straight pin lock before installing
the gear.
5. INSPECT CAMSHAFT TIMING EXHAUST GEAR
ASSEMBLY
(a) Clamp the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft in the
vise.
(b) Put the camshaft timing exhaust gear assembly and
camshaft together by aligning the key groove and
straight pin.
(c) Lightly press the camshaft timing gear against the
camshaft, and turn the camshaft timing gear
assembly. Push further at the position where the pin
enters the groove.
NOTICE:
Be sure not to turn the camshaft timing exhaust
gear in the retard direction (the right angle).
(d) Check that there is no clearance between the gear's
flange and the camshaft.
(e) Tighten the flange bolt with the camshaft timing
exhaust gear assembly fixed.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
(f) Check the camshaft timing exhaust gear lock.
(1) Make sure that the camshaft timing exhaust
gear assembly is locked.
A095160E02
A109635E02
A107564
Page 1052 of 3000

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–105
EM
(g) Release the lock pin.
(1) Cover the 4 oil paths of the cam journal with
vinyl tape as shown in the illustration.
HINT:
4 oil paths are provided in the groove. Plug 2
paths with rubber pieces.
(2) 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.
(3) Apply approximately 200 kPa (2.0 kgf/cm
2, 28
psi) of air pressure to the 2 broken paths (the
advance side path and the retard side path).
CAUTION:
Cover the paths with a piece of cloth when
applying pressure to keep oil from
splashing.
(4) Make sure 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.
(5) 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.
A106103E01
A106104E01
A106105E02
Page 1053 of 3000

EM–1062GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
(h) Check for smooth rotation.
(1) Turn the camshaft timing exhaust gear within
its movable range (18.5
) 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.
(i) Check the lock at the most advanced position.
(1) Make sure that the camshaft timing exhaust
gear is locked at the most advanced position.
(j) Remove the flange bolt and camshaft timing
exhaust gear.
NOTICE:
• Be sure not to remove the other 4 bolts.
• If planning to reuse the gear, be sure to
release the straight pin lock before installing
the gear.
6. INSPECT CYLINDER HEAD SET BOLT
(a) Using vernier calipers, measure the minimum
diameter of the elongated thread at the measuring
point.
Standard outside diameter:
10.85 to 11.00 mm (0.4272 to 0.4331 in.)
Minimum outside diameter:
10.70 mm (0.4213 in.)
Measuring Point:
103 mm (4.06 in.)
HINT:
If a visual check reveals no excessively thin areas,
check the center of the bolt and find the area that
has the lowest diameter.
If the diameter is less than the minimum, replace the
cylinder head bolt.
A095162E02
A122880E03
Page 1054 of 3000

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–107
EM
7. INSPECT CHAIN SUB-ASSEMBLY
(a) Pull the chain with a force of 147 N (15 kgf, 33 lbf)
as shown in the illustration.
(b) Using vernier calipers, measure the length of 15
links.
Maximum chain elongation:
136.9 mm (5.390 in.)
NOTICE:
Perform the measurement at 3 random places.
Use the average of the measurements.
If the elongation is greater than the maximum,
replace the chain.
8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY
(a) Pull the chain with a force of 147 N (15 kgf, 33 lbf)
as shown in the illustration.
(b) Using vernier calipers, measure the length of 15
links.
Maximum chain elongation:
137.6 mm (5.417 in.)
NOTICE:
Perform the measurement at 3 random places.
Use the average of the measurements.
If the elongation is greater than the maximum,
replace the chain.
9. INSPECT CRANKSHAFT TIMING SPROCKET
(a) Wrap the chain around the sprocket.
(b) Using vernier calipers, measure the sprocket
diameter with the chain.
Minimum sprocket diameter (with chain):
61.4 mm (2.417 in.)
HINT:
The vernier calipers must contact the chain rollers
for the measurement.
If the diameter is less than the minimum, replace the
chain and sprocket.
10. INSPECT IDLE SPROCKET ASSEMBLY
(a) Wrap the chain around the sprocket.
(b) Using vernier calipers, measure the sprocket
diameter with the chain.
Minimum sprocket diameter (with chain):
61.4 mm (2.417 in.)
HINT:
The vernier calipers must contact the chain rollers
for the measurement.
If the diameter is less than the minimum, replace the
chain and sprocket.
A135727E01
A135727E04
A109646
A109647
Page 1055 of 3000

EM–1082GR-FE ENGINE MECHANICAL – ENGINE UNIT
EM
11. 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.
12. 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.
13. 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.
A109648
A120673
A097905E06
A106108E01
Page 1056 of 3000

2GR-FE ENGINE MECHANICAL – ENGINE UNITEM–109
EM
14. 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.
15. 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.
16. 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.
17. 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.
A106109E01
A106110E01
A106111E01
A106112E01