2Tr-Fbe Engine Mechanical. Engine Unit Inspection

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

2Tr-Fbe Engine Mechanical. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

Engine Unit -- Inspection

1. INSPECT CHAIN SUB-ASSEMBLY

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 16 links.
Maximum chain elongation:
147.5 mm (5.81 in.)
Text in Illustration
*1
Measuring Area
If the elongation is more than the maximum, replace the chain sub-assembly.
NOTICE:
Perform the measurement at 3 random places.

Text in Illustration
*1	Measuring Area

2. INSPECT NO. 2 CHAIN SUB-ASSEMBLY

Pull the chain with a force of 147 N (15 kgf, 33.0 lbf).

Using a vernier caliper, measure the length of 16 links.
Maximum chain elongation:
123.6 mm (4.87 in.)
If the elongation is more than the maximum, replace the No. 2 chain sub-assembly.
NOTICE:
Perform the measurement at 3 random places.

3. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly.
Text in Illustration
*1
Plunger
*2
Stopper Plate

Text in Illustration
*1	Plunger
*2	Stopper Plate

4. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

Move the stopper plate downward to release the lock. Push the plunger and check that it moves smoothly.
Text in Illustration
*1
Plunger
*2
Stopper Plate

Text in Illustration
*1	Plunger
*2	Stopper Plate

5. INSPECT CAMSHAFT TIMING SPROCKET

Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip.
Minimum distance:
1.0 mm (0.0394 in.)
Text in Illustration

Worn Area
If the distance is less than the minimum, replace the camshaft timing sprocket.
If the worn area is too small or difficult to distinguish from a normal area, perform the following 2 steps.

Text in Illustration
	Worn Area

Wrap the chain around the sprocket.

Using a vernier caliper, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain):
113.8 mm (4.48 in.)
HINT:
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the chain and camshaft timing sprocket.

6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

Measure the distance between the most worn out timing gear tip and the beginning of the worn area below the tip.
Minimum distance:
1.0 mm (0.0394 in.)
Text in Illustration

Worn Area
If the distance is less than the minimum, replace the camshaft timing gear assembly.
If the worn area is too small or difficult to distinguish from a normal area, perform the following 2 steps.

Text in Illustration
	Worn Area

Wrap the chain around the timing gear.

Using a vernier caliper, measure the sprocket diameter with the chain.
Minimum timing gear diameter (with chain):
113.8 mm (4.48 in.)
HINT:
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the chain and camshaft timing gear assembly.

7. INSPECT CRANKSHAFT TIMING SPROCKET

Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip.
Minimum distance:
1.0 mm (0.0394 in.)
Text in Illustration

Worn Area
If the distance is less than the minimum, replace the crankshaft timing sprocket.
If the worn area is too small or difficult to distinguish from a normal area, perform the following 2 steps.

Text in Illustration
	Worn Area

Wrap the chain around the timing sprocket.

Using a vernier caliper, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain):
59.4 mm (2.34 in.)
HINT:
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the chain and crankshaft timing sprocket.

8. INSPECT CHAIN TENSIONER SLIPPER

Using a vernier caliper, measure the tensioner slipper wear.
Maximum wear:
2.0 mm (0.0787 in.)
Text in Illustration
*1
Wear
If the wear is more than the maximum, replace the chain tensioner slipper.

Text in Illustration
*1	Wear

9. INSPECT NO. 1 CHAIN VIBRATION DAMPER

Using a vernier caliper, measure the vibration damper wear.
Maximum wear:
2.0 mm (0.0787 in.)
Text in Illustration
*1
Wear
If the wear is more than the maximum, replace the No. 1 chain vibration damper.

Text in Illustration
*1	Wear

10. INSPECT TIMING CHAIN GUIDE

Using a vernier caliper, measure the chain guide wear.
Maximum wear:
0.5 mm (0.0197 in.)
Text in Illustration

Wear
If the wear is more than the maximum, replace the timing chain guide.

Text in Illustration
	Wear

11. INSPECT NO. 2 CRANKSHAFT TIMING SPROCKET

Wrap the chain around the sprocket.

Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

Using a vernier caliper, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain):
96.7 mm (3.81 in.)
HINT:
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the chain and No. 2 crankshaft timing sprocket.

12. INSPECT BALANCE SHAFT DRIVE GEAR SUB-ASSEMBLY

Wrap the chain around the drive gear.

Using a vernier caliper, measure the drive gear diameter with the chain.
Minimum drive gear diameter (with chain):
75.9 mm (2.99 in.)
HINT:
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the chain and balance shaft drive gear sub-assembly.

13. INSPECT NO. 2 CHAIN VIBRATION DAMPER

Using a vernier caliper, measure the vibration damper wear.
Maximum wear:
1.0 mm (0.0394 in.)
Text in Illustration
*1
Wear
If the wear is more than the maximum, replace the No. 2 chain vibration damper.

Text in Illustration
*1	Wear

14. INSPECT NO. 3 CHAIN VIBRATION DAMPER

Using a vernier caliper, measure the vibration damper wear.
Maximum wear:
1.0 mm (0.0394 in.)
Text in Illustration
*1
Wear
If the wear is more than the maximum, replace the No. 3 chain vibration damper.

Text in Illustration
*1	Wear

15. INSPECT NO. 4 CHAIN VIBRATION DAMPER

Using a vernier caliper, measure the vibration damper wear.
Maximum wear:
1.0 mm (0.0394 in.)
Text in Illustration
*1
Wear
If the wear is more than the maximum, replace the No. 4 chain vibration damper.

Text in Illustration
*1	Wear

16. INSPECT CYLINDER HEAD SET BOLT

Using a vernier caliper, measure the diameter of the most elongated threads in the measuring area.
Standard outside diameter:
10.76 to 10.97 mm (0.424 to 0.432 in.)
Minimum outside diameter:
10.40 mm (0.409 in.)
Distance:
30 mm (1.18 in.)
Text in Illustration
*1
Measuring area
*2
Distance
If a visual check reveals no excessively thin areas, check the center of the measuring area (see illustration) and find the area that has the smallest diameter.
If the diameter is less than the minimum, replace the cylinder head set bolt.

Text in Illustration
*1	Measuring area
*2	Distance

17. INSPECT VALVE LASH ADJUSTER ASSEMBLY

NOTICE:

Keep the lash adjuster free from dirt and foreign objects.
Only use clean engine oil.

Place the lash adjuster into a container full of new engine oil.
Text in Illustration
*1
Tapered Part
*2
Plunger
*3
Low Pressure Chamber
*4
Check Ball
*5
High Pressure Chamber
*a
CORRECT
*b
INCORRECT

Text in Illustration
*1	Tapered 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.

18. INSPECT CAMSHAFT

Check the camshaft runout.
1. Place the camshaft on V-blocks.
2. 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.

Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
42.855 to 42.955 mm (1.687 to 1.691 in.)
Minimum cam lobe height:
42.855 mm (1.687 in.)
If the cam lobe height is less than the minimum, replace the camshaft.

Using a micrometer, measure the journal diameter.
Standard Journal Diameter:
Item
Specified Condition
No. 1 journal
35.949 to 35.965 mm (1.415 to 1.416 in.)
Other journal
26.959 to 26.975 mm (1.061 to 1.062 in.)
If the journal diameter is not as specified, check the oil clearance.

19. INSPECT NO. 2 CAMSHAFT

Check the camshaft runout.
1. Place the camshaft on V-blocks.
2. 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.

Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
42.854 to 42.954 mm (1.687 to 1.691 in.)
Minimum cam lobe height:
42.854 mm (1.687 in.)
If the cam lobe height is less than the minimum, replace the camshaft.

Using a micrometer, measure the journal diameter.
Standard Journal Diameter:
Item
Specified Condition
No. 1 journal
35.949 to 35.965 mm (1.415 to 1.416 in.)
Other journal
26.959 to 26.975 mm (1.061 to 1.062 in.)
If the journal diameter is not as specified, check the oil clearance.

20. INSPECT CAMSHAFT THRUST CLEARANCE

Install the camshafts (HILUX_TGN26 RM000000YMY01EX.html).

Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance:
0.10 to 0.24 mm (0.00394 to 0.00945 in.)
Maximum thrust clearance:
0.26 mm (0.0102 in.)
If the thrust clearance is more than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

21. INSPECT CAMSHAFT OIL CLEARANCE

Clean the bearing caps and camshaft journals.

Place the camshafts on the cylinder head.

Lay a strip of Plastigage across each of the camshaft journals.
Text in Illustration
*1
Plastigage

Install the bearing caps (HILUX_TGN26 RM000000YMY01EX_01_0005.html).
NOTICE:
Do not turn the camshafts.

Remove the bearing caps (HILUX_TGN26 RM000000YN001CX_01_0008.html).

Measure the Plastigage at its widest point.
Standard Oil Clearance:
Item
Specified Condition
No. 1 journal
0.035 to 0.072 mm (0.00138 to 0.00283 in.)
Other journals
0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum oil clearance:
0.08 mm (0.00315 in.)
Text in Illustration
*1
Plastigage
If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the cylinder head sub-assembly.

Completely remove the Plastigage.

22. INSPECT EXHAUST MANIFOLD

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.

Item	Specified Condition
No. 1 journal	35.949 to 35.965 mm (1.415 to 1.416 in.)
Other journal	26.959 to 26.975 mm (1.061 to 1.062 in.)