Engine Unit: Inspection

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INSPECT CHAIN SUB-ASSEMBLY
1. Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in Fig 1.
2. Using vernier calipers, measure the length of 16 links.
  Maximum chain elongation: 147.5 mm (5.807 in.)
  
  If the elongation is greater than the maximum, replace the chain.
  
  NOTE: Perform the same measurement by pulling at random in 3 or more places to obtain an average.
  
  Fig 1: Measuring Length Of Links Using Vernier Calipers (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO.2 CHAIN SUB-ASSEMBLY
1. Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in Fig 2.
2. Using vernier calipers, measure the length of 16 links.
  Maximum chain elongation: 123.6 mm (4.866 in.)
  
  If the elongation is greater than the maximum, replace the chain.
  
  NOTE: Perform the same measurement by pulling at random in 3 or more places to obtain an average.
  
  Fig 2: Measuring Length Of Links Using Vernier Calipers (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY
1. Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly.
  
  Fig 3: Moving Stopper Plate Upward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
1. Move the stopper plate downward to release the lock. Push the plunger and check that it moves smoothly.
  
  Fig 4: Moving Stopper Plate Downward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
1. 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 (0.039 in.)
  
  If the distance is less than the minimum, replace the sprocket.
  
  HINT:
  
  If the worn area is too small or difficult to distinguish from a normal area, perform steps ( b) and ( c) below.
  
  Fig 5: Measuring Distance Between Most Worn Out Sprocket Tip & Beginning Of Worn Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Wrap the chain around the sprocket.
3. Using vernier calipers, measure the sprocket diameter with the chain.
  Minimum sprocket diameter (with chain): 113.8 mm (4.480 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.
INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
1. 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 (0.039 in.)
  
  If the distance is less than the minimum, replace the timing gear.
  
  HINT:
  
  If the worn area is too small or difficult to distinguish from a normal area, perform steps ( b) and ( c) below.
  
  Fig 6: Measuring Distance Between Most Worn Out Timing Gear Tip & Beginning Of Worn Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Wrap the chain around the timing gear.
3. Using vernier calipers, measure the sprocket diameter with the chain.
  Minimum sprocket diameter (with chain): 113.8 mm (4.480 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 timing gear.
INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
1. 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 (0.039 in.)
  
  If the distance is less than the minimum, replace the sprocket.
  
  HINT:
  
  If the worn area is too small or difficult to distinguish from a normal area, perform steps ( b) and ( c) below.
  
  Fig 7: Measuring Distance Between Most Worn Out Sprocket Tip & Beginning Of Worn Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Wrap the chain around the drive sprocket.
3. Using vernier calipers, measure the sprocket diameter with the chain.
  Minimum sprocket diameter (with chain): 59.4 mm (2.338 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.
INSPECT CHAIN TENSIONER SLIPPER
1. Using vernier calipers, measure the tensioner slipper wear.
  Maximum wear: 2.0 mm (0.079 in.)
  
  If the wear is greater than the maximum, replace the tensioner slipper.
  
  Fig 8: Measuring Tensioner Slipper Wear Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 CHAIN VIBRATION DAMPER
1. Using vernier calipers, measure the vibration damper wear.
  Maximum wear: 2.0 mm (0.079 in.)
  
  If the wear is greater than the maximum, replace the vibration damper.
  
  Fig 9: Measuring Vibration Damper Wear Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TIMING CHAIN GUIDE
1. Using vernier calipers, measure the chain guide wear.
  Maximum wear: 0.5 mm (0.020 in.)
  
  If the wear is greater than the maximum, replace the timing chain guide.
  
  Fig 10: Measuring Chain Guide Wear Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 CRANKSHAFT TIMING SPROCKET
1. Wrap the chain around the sprocket.
2. Using vernier calipers, measure the sprocket diameter with the chain.
  Minimum sprocket diameter (with chain): 96.7 mm (3.807 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.
  
  Fig 11: Measuring Sprocket Diameter With Chain Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT BALANCER SHAFT DRIVE GEAR SUB-ASSEMBLY
1. Wrap the chain around the sprocket.
2. Using vernier calipers, measure the sprocket diameter with the chain.
  Minimum sprocket diameter (with chain): 75.9 mm (2.988 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.
  
  Fig 12: Measuring Sprocket Diameter With Chain Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 CHAIN VIBRATION DAMPER
1. Using vernier calipers, measure the vibration damper No.2 wear.
  Maximum wear: 1.0 mm (0.039 in.)
  
  If the wear is greater than the maximum, replace the vibration damper.
  
  Fig 13: Measuring Vibration Damper No. 2 Wear Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 CHAIN VIBRATION DAMPER
1. Using vernier calipers, measure the vibration damper No.3 wear.
  Maximum wear: 1.0 mm (0.039 in.)
  
  If the wear is greater than the maximum, replace the vibration damper.
  
  Fig 14: Measuring Vibration Damper No. 3 Wear Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 4 CHAIN VIBRATION DAMPER
1. Using vernier calipers, measure the vibration damper No.4 wear.
  Maximum wear: 1.0 mm (0.039 in.)
  
  If the wear is greater than the maximum, replace the vibration damper.
  
  Fig 15: Measuring Vibration Damper No. 4 Wear Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER HEAD SET BOLT
1. Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point.
  Standard outside diameter: 10.76 to 10.97 mm (0.4236 to 0.4319 in.)
  
  Minimum outside diameter: 10.40 mm (0.4094 in.)
  
  Fig 16: Measuring Minimum Diameter Of Elongated Thread Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  - If a visual check reveals no excessively thin areas, check the center of the bolt (see Fig 16) and find the area that has the lowest diameter.
  - If the diameter is less than the minimum, replace the cylinder head bolt.
INSTALL CRANKSHAFT PULLEY SET CRANKSHAFT KEY
1. Install the 2 pulley keys to the crankshaft.
  
  Fig 17: Installing Pulley Keys To Crankshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 4 CHAIN VIBRATION DAMPER
1. Install the vibration damper No.4 with the 2 bolts.
  Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf)
  
  Fig 18: Installing Vibration Damper No. 4 With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT VALVE LASH ADJUSTER ASSEMBLY
NOTE:
- Keep the lash adjuster free from dirt and foreign objects.
- Only use clean engine oil.
1. Place the lash adjuster into a container full of engine oil.
2. Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the checkball inside the plunger.
  SST 09276-75010
3. Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
4. Check the movement of the plunger and bleed the air.
  OK: Plunger moves up and down.
  
  NOTE: When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the checkball as shown in the illustration. If the checkball is not pressed, air will not bleed.
5. After bleeding the air, remove the SST. Then quickly and firmly press the plunger with a finger.
  OK: Plunger is very difficult to move.
  
  If the result is not as specified, replace the lash adjuster.
  
  Fig 19: Inserting SST's Tip Into Lash Adjuster's Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER HEAD FOR FLATNESS
1. Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of contacting the cylinder block and manifolds.
  Maximum warpage: 0.05 mm (0.0020 in.)
  
  If the warpage is greater than the maximum, replace the cylinder head.
  
  Fig 20: Measuring Warpage Of Contact Surface Of Contacting Cylinder Block & Manifolds Using Straight Edge & Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER HEAD FOR CRACKS
1. Using a dye penetrate, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head.
  
  Fig 21: Checking Intake Ports, Exhaust Ports & Cylinder Surface For Cracks Using Dye Penetrate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INTAKE VALVE SEAT
1. Apply a light coat of Prussian blue (or white lead) to the valve face.
2. Lightly press the valve face against the valve seat.
3. Check the valve face and valve seat by using the following procedure.
  1. If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.
  2. If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat.
  3. Check that the valve seat contacts in the middle of the valve face with the width between 1.0 and 1.4 mm (0.039 and 0.055 in.).
    
    Fig 22: Measuring Intake Valve Seat Width
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT EXHAUST VALVE SEAT
1. Apply a light coat of Prussian blue (or white lead) to the valve face.
2. Lightly press the valve face against the valve seat.
3. Check the valve face and valve seat by using to the following procedure.
  1. If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.
  2. If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat.
  3. Check that the valve seat contacts in the middle of the valve face with the width between 1.0 and 1.4 mm (0.039 and 0.055 in.).
    
    Fig 23: Measuring Exhaust Valve Seat Width
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CAMSHAFT

Check the camshaft for 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 (0.0012 in.)
  
  If the circle runout is greater than the maximum, replace the camshaft.
  
  Fig 24: Measuring Circle Runout At Center Journal Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a micrometer, measure the cam lobe height.
Standard cam lobe height: 42.855 to 42.955 mm (1.6872 to 1.6911 in.)

Minimum cam lobe height: 42.855 mm (1.6872 in.)

If the cam lobe height is less than the minimum, replace the camshaft.

Fig 25: Measuring Cam Lobe Height Using Micrometer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the journal diameter.

Standard journal diameter

JOURNAL DIAMETER SPECIFICATION

No.1 journal	35.949 to 35.965 mm (1.4153 to 1.4159 in.)
Other journal	26.959 to 26.975 mm (1.0614 to 1.0620 in.)

If the journal diameter is not as specified, check the oil clearance.

Fig 26: Measuring Journal Diameter Using Micrometer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT NO. 2 CAMSHAFT

Check the camshaft for 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 (0.0012 in.)
  
  If the circle runout is greater than the maximum, replace the camshaft.
  
  Fig 27: Measuring Circle Runout At Center Journal Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a micrometer, measure the cam lobe height.
Standard cam lobe height: 42.854 to 42.954 mm (1.687 to 1.6911 in.)

Minimum cam lobe height: 42.854 mm (1.6872 in.)

If the cam lobe height is less than the minimum, replace the camshaft.

Fig 28: Measuring Cam Lobe Height Using Micrometer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the journal diameter.

Standard journal diameter

JOURNAL DIAMETER SPECIFICATION

No.1 journal	35.949 to 35.965 mm (1.4153 to 1.4159 in.)
Other journal	26.959 to 26.975 mm (1.0614 to 1.0620 in.)

If the journal diameter is not as specified, check the oil clearance.

Fig 29: Measuring Journal Diameter Using Micrometer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CAMSHAFT THRUST CLEARANCE
1. Install the camshafts.
2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
  Standard thrust clearance: 0.10 to 0.24 mm (0.004 to 0.009 in.)
  
  Maximum thrust clearance: 0.26 mm (0.010 in.)
  
  If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.
  
  Fig 30: Measuring Thrust Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.
Install the bearing caps.
Torque: 16 N*m (160 kgf*cm, 11 ft.*lbf)

NOTE: Do not turn the camshaft.
Remove the bearing caps.

Fig 31: Laying Strip Of Plastigage Across Of Camshaft Journals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Measure the Plastigage at its widest point.

Standard oil clearance

PLASTIGAGE SPECIFICATION

No.1 journal	0.035 to 0.072 mm (0.0014 to 0.0029 in.)
Other journal	0.025 to 0.062 mm (0.00098 to 0.0024 in.)

Maximum oil clearance: 0.08 mm (0.003 in.)

If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the cylinder head.

Completely remove the Plastigage.

Fig 32: Measuring Plastigage At Widest Point
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT INNER COMPRESSION SPRING
1. Using vernier calipers, measure the free length of the inner compression spring.
  Free length: 48.53 mm (1.9106 in.)
  
  If the free length is not as specified, replace the spring.
  
  Fig 33: Measuring Free Length Of Inner Compression Spring Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a steel square, measure the deviation of the inner compression spring.
  Maximum deviation: 1.5 mm (0.059 in.)
  
  Maximum angle (reference): 2°
  
  If the deviation is greater than the maximum, replace the spring.
  
  Fig 34: Measuring Deviation Of Inner Compression Spring Using Steel Square
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INTAKE VALVE
1. Using vernier calipers, measure the valve's overall length.
  Standard overall length: 106.26 mm (4.1835 in.)
  
  Minimum overall length: 105.96 mm (4.1716 in.)
  
  If the overall length is less than the minimum, replace the valve.
  
  Fig 35: Measuring Valve's Overall Length Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the diameter of the valve stem.
  Valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 in.)
  
  Fig 36: Measuring Diameter Of Valve Stem Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using vernier calipers, measure the valve head margin thickness.
  Standard margin thickness: 1.05 to 1.45 mm (0.0413 to 0.0571 in.)
  
  Minimum margin thickness: 0.50 mm (0.0197 in.)
  
  Thickness If the margin thickness is less than the minimum, replace the valve.
  
  Fig 37: Measuring Valve Head Margin Thickness Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT EXHAUST VALVE
1. Using vernier calipers, measure the valve's overall length.
  Standard overall length: 106.74 mm (4.2024 in.)
  
  Minimum overall length: 106.44 mm (4.1905 in.)
  
  If the overall length is less than the minimum, replace the valve.
  
  Fig 38: Measuring Valve's Overall Length Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the diameter of the valve stem.
  Valve stem diameter: 5.465 to 5.480 mm (0.2151 to 0.2157 in.)
  
  Fig 39: Measuring Diameter Of Valve Stem Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using vernier calipers, measure the valve head margin thickness.
  Standard margin thickness: 1.2 to 1.6 mm (0.0472 to 0.0630 in.)
  
  Minimum margin thickness: 0.50 mm (0.0197 in.)
  
  If the margin thickness is less than the minimum, replace the valve.
  
  Fig 40: Measuring Valve Head Margin Thickness Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT VALVE GUIDE BUSHING
1. Using a caliper gauge, measure the inside diameter of the guide bush.
  Bush inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.)
2. Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.
  Standard oil clearance:
  
  0.025 to 0.060 mm (0.0010 to 0.0024 in.) (Intake)
  
  0.030 to 0.065 mm (0.0012 to 0.0026 in.) (Exhaust)
  
  Fig 41: Measuring Inside Diameter Of Guide Bush Using Caliper Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum oil clearance:
  
  0.08 mm (0.0032 in.) (Intake)
  
  0.10 mm (0.0039 in.) (Exhaust)
  
  HINT:
  - If the clearance is greater than the maximum, replace the intake valve and intake guide bush.
  - If the clearance is greater than the maximum, replace the exhaust valve and exhaust guide bush.
INSPECT CONNECTING ROD THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
  Standard thrust clearance: 0.150 to 0.350 mm (0.0059 to 0.0138 in.)
  
  Maximum thrust clearance: 0.40 mm (0.016 in.)
  
  If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
  
  Fig 42: Measuring Thrust Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CONNECTING ROD OIL CLEARANCE

Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly.
HINT:

The matchmarks on the connecting rods and caps are for ensuring the correct reassembly.
Remove the 2 connecting rod cap bolts.
Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
HINT:

Fig 43: Removing Connecting Rod Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Keep the lower bearing inserted to the connecting rod cap.
Clean the crank pin and bearing.
Check the crank pin and bearing for pitting and scratches.
Lay a strip of Plastigage on the crank pin.

Fig 44: Laying Strip Of Plastigage On Crank Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check that the front mark of the connecting rod cap is facing forward.

Fig 45: Checking Front Mark Of Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the connecting rod cap.
NOTE: Do not turn the crankshaft.
Remove the 2 bolts and connecting rod cap (see steps ( b) and ( c) above).

Fig 46: Removing Bolts & Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Measure the Plastigage at its widest point.

Standard oil clearance: 0.024 to 0.049 mm (0.0009 to 0.0019 in.)

Maximum oil clearance: 0.066 mm (0.0026 in.)

If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, replace 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 and 3 mark on its surface.

Reference

Crankshaft pin diameter

CRANKSHAFT PIN DIAMETER SPECIFICATION

Mark	Thickness
4	52.989 to 53.002 mm (2.0862 to 2.0867 in.)
5	52.989 to 53.002 mm (2.0862 to 2.0867 in.)
6	52.989 to 53.002 mm (2.0862 to 2.0867 in.)

Standard bearing center wall thickness

BEARING CENTER WALL THICKNESS SPECIFICATION

Mark	Thickness
4	1.484 to 1.487 mm (0.0584 to 0.0585 in.)
5	1.488 to 1.490 mm (0.0586 to 0.0587 in.)
6	1.491 to 1.493 mm (0.0587 to 0.0588 in.)

Fig 47: Measuring Plastigage At Widest

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Completely remove the Plastigage.

INSPECT CRANKSHAFT THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
  Standard thrust clearance: 0.020 to 0.220 mm (0.0008 to 0.0087 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: 2.440 to 2.490 mm (0.0961 to 0.0980 in.)
  
  Fig 48: Measuring Thrust Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CLEAN WITH PIN PISTON SUB-ASSEMBLY
1. Using a gasket scraper, remove the carbon from the piston top.
  
  Fig 49: Removing Carbon From Piston Top Using Gasket Scraper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
  
  Fig 50: Cleaning Piston Ring Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using solvent and a brush, thoroughly clean the piston.
  NOTE: Do not use a wire brush.
INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY
1. Check the oil nozzles for damage or clogging.
  If necessary, replace the oil nozzle.
INSPECT BALANCE SHAFT THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the balancer shaft back and forth.
  Standard thrust clearance: 0.07 to 0.13 mm (0.0027 to 0.0051 in.)
  
  Maximum thrust clearance: 0.20 mm (0.0079 in.)
  
  If the thrust clearance is greater than the maximum, replace the balancer shaft thrust washer. If necessary, replace the balancer shaft.
  
  Fig 52: Measuring Thrust Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER BLOCK FOR FLATNESS
1. Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.
  Maximum warpage: 0.05 mm (0.0020 in.)
  
  If the warpage is greater than the maximum, replace the cylinder block.
  
  Fig 53: Measuring Warpage Of Contact Surface Of Cylinder Head Gasket Using Straight Edge & Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 4 cylinders. If necessary, replace the cylinder block.
  
  Fig 54: Identifying Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER BORE
1. Using a cylinder gauge, measure the cylinder bore diameter at positions A in the thrust and axial directions.
  Standard diameter: 94.990 to 95.003 mm (3.7398 to 3.7403 in.)
  
  Maximum difference diameter: 0.2 mm (0.008 in.)
  
  If the diameter is greater than the maximum, rebore all the 4 cylinders. If necessary, replace the cylinder block.
  
  Fig 55: Measuring Cylinder Bore Diameter Using Cylinder Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect the cylinder ridge.
  If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.
  
  Fig 56: Grinding Top Of Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CLEAN CYLINDER BLOCK
1. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Using a soft brush and solvent, thoroughly clean the cylinder block.
  
  Fig 57: Removing Gasket Material From Top Surface Of Cylinder Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PISTON DIAMETER
1. Using a micrometer, measure the piston diameter at right angles to the piston center line, the indicated distance from the piston end.
  Distance: 9.3 mm (0.366 in.)
  
  Piston diameter: 94.941 to 94.971 mm (3.7378 to 3.7390 in.) (for standard)
  
  Fig 58: Measuring Piston Diameter Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PISTON OIL CLEARANCE

Measure the cylinder bore diameter in the thrust directions (see step 20).
Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.019 to 0.052 mm (0.0007 to 0.0020 in.)

If the oil clearance is greater than the standard, replace all the pistons and rebore all the cylinders. If necessary, replace the cylinder block.

HINT:
- Bore all the cylinders for the O/S piston outside diameter.
- Replace all the piston rings with ones to match the O/S pistons.

If the oil clearance is greater than the standard.

Prepare 4 new O/S pistons.
O/S 0.50 piston diameter: 95.441 to 95.451 mm (3.7575 to 3.7579 in.)
Using a micrometer, measure the piston diameter at right angles to the piston center line, the indicated distance from the piston end.
Distance: 9.3 mm (0.366 in.)

Calculate the amount each cylinder is to be rebored as follows:

Size to be rebored = P + C - H

PISTON DIAMETER SPECIFICATION

P	Piston diameter
C	Piston clearance: 0.019 to 0.052 mm (0.0007 to 0.0020 in.)
H	Allowance for honing: 0.02 mm (0.0008 in.) or less

Bore and hone the cylinders to calculated dimensions.
Maximum honing: 0.02 mm (0.0008 in.)

NOTE: Excess honing will destroy the finished roundness.

INSPECT RING GROOVE CLEARANCE

Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

Ring groove clearance

RING GROOVE CLEARANCE SPECIFICATION

No.1	0.020 to 0.075 mm (0.0008 to 0.0030 in.)
No.2	0.020 to 0.065 mm (0.0008 to 0.0026 in.)
Oil	0.020 to 0.070 mm (0.0008 to 0.0028 in.)

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

Fig 59: Measuring Ring Groove Clearance Using Feeler Gauge

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PISTON RING END GAP

Insert the piston ring into the cylinder bore.
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.

Fig 60: Inserting Piston Ring Into Cylinder Bore
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a feeler gauge, measure the end gap.

Standard end gap

END GAP SPECIFICATION

No.1	0.22 to 0.34 mm (0.0087 to 0.0134 in.)
No.2	0.45 to 0.57 mm (0.0177 to 0.0224 in.)
Oil	0.10 to 0.40 mm (0.0039 to 0.0157 in.)

Maximum end gap

END GAP SPECIFICATION

No.1	0.90 mm (0.0354 in.)
No.2	1.36 mm (0.0535 in.)
Oil	0.75 mm (0.0295 in.)

Fig 61: Measuring End Gap Using Feeler Gauge

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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, rebore all the 4 cylinders or replace the cylinder block.

INSPECT PISTON PIN OIL CLEARANCE
1. Using a caliper gauge, measure the inside diameter of the piston pin hole.
  Piston pin hole inside diameter: 22.001 to 22.010 mm (0.8662 to 0.8665 in.)
  
  Fig 62: Measuring Inside Diameter Of Piston Pin Hole Using Caliper Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the piston pin diameter.
  Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 in.)
  
  Fig 63: Measuring Piston Pin Diameter Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
  Bushing inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 in.)
4. 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 0.00028 in.)
  
  Maximum oil clearance: 0.010 mm (0.0004 in.)
  
  HINT:
  
  If the oil clearance is greater than the maximum, replace the piston and piston pin as a set.
  
  Fig 64: Measuring Inside Diameter Of Connecting Rod Bushing Using Caliper Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. 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: 0.025 mm (0.0010 in.)
6. If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin as a set.
  
  Fig 65: Identifying Connecting Rod Bushing Inside Diameter Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CONNECTING ROD
1. Using a rod aligner and feeler gauge, check the connecting rod alignment.
  1. Check for bend.
    Maximum bend: 0.03 mm (0.0012 in.) per 100 mm (3.94 in.)
    
    If the bend is greater than the maximum, replace the connecting rod sub-assembly.
    
    Fig 66: Checking Connecting Rod Alignment Using Rod Aligner & Feeler Gauge
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 sub-assembly.
    
    Fig 67: Checking Connecting Rod Twist
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CONNECTING ROD BOLT
1. Using vernier calipers, 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.
  
  Fig 68: Measuring Tension Portion Diameter Of Bolt Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CRANKSHAFT

Inspect for circle runout.
1. Place the crankshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
  Maximum circle runout: 0.03 mm (0.0012 in.)
  
  If the circle runout is greater than the maximum, replace the crankshaft.
  
  Fig 69: Measuring Crankshaft Circle Runout Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the main journals.

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

Standard journal diameter:

JOURNAL DIAMETER SPECIFICATION

No.3 journal	59.981 to 59.994 mm (2.3615 to 2.3620 in.)
Except No.3 journal	59.987 to 60.000 mm (2.3619 to 2.3622 in.)

If the diameter is not as specified, check the oil clearance (see step 30). If necessary, replace the crankshaft.

Check each main journal for taper and out-of-round as shown in Fig 70.
Maximum taper and out-of-round: 0.005 mm (0.0002 in.)

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

Fig 70: Measuring Diameter Of Main Journal Using Micrometer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the crank pin.
1. Using a micrometer, measure the diameter of each crank pin.
  Diameter: 52.989 to 53.002 mm (2.0862 to 2.0867 in.)
  
  If the diameter is not as specified, check the oil clearance (see step 2). If necessary, replace the crankshaft.
2. Check each crank pin for taper and out-of-round as shown in Fig 71.
  Maximum taper and out-of-round: 0.003 mm (0.0001 in.)
  
  If the taper and out-of-round is greater than the maximum, replace the crankshaft.

INSPECT CRANKSHAFT OIL CLEARANCE

HINT:

Keep the lower bearings and crankshaft bearing caps together.
Arrange the thrust washers in the correct order.
Keep the upper crankshaft bearings and upper thrust washers together with the cylinder block.

Clean each main journal and bearing.
Check each main journal and bearing for pitting and scratches.
If the journal or bearing is damaged, replace the bearing.
Place the crankshaft on the cylinder block.
Lay a strip of Plastigage across each journal.

Fig 72: Laying Strip Of Plastigage Across Journal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the 5 crankshaft bearing caps in their proper locations.
Install the 5 crankshaft bearing caps with the 10 bolts (see step 49).
NOTE: Do not turn the crankshaft.
Remove the 10 bolts and 5 crankshaft bearing caps.

Fig 73: Installing Crankshaft Bearing Caps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Measure the Plastigage at its widest point.

Standard oil clearance

BEARING CAPS SPECIFICATION

Bearing Cap	Standard
No.3	0.030 to 0.055 mm (0.0012 to 0.0022 in.)
Others	0.024 to 0.049 mm (0.0009 to 0.0019 in.)

Maximum oil clearance: 0.10 mm (0.0039 in.)

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

HINT:

If replacing the cylinder block, measure the bearing standard clearance.
If replacing a bearing, first check the number on the cylinder block for the bearing's respective journal. Then replace the bearing with one that has the same number. Each bearing's standard thickness is indicated by a 1, 2 or 3 mark on its surface.

Reference

Cylinder block main journal bore diameter

MAIN JOURNAL BORE DIAMETER SPECIFICATION

Mark	Diameter
1	64.004 to 64.010 mm (2.5198 to 2.5201 in.)
2	64.011 to 64.016 mm (2.5201 to 2.5203 in.)
3	64.017 to 64.022 mm (2.5203 to 2.5206 in.)

Standard bearing center wall thickness

BEARING CENTER WALL THICKNESS SPECIFICATION

Mark	Thickness
1	1.987 to 1.990 mm (0.0782 to 0.0783 in.)
2	1.991 to 1.993 mm (0.0784 to 0.0785 in.)
3	1.994 to 1.996 mm (0.0785 to 0.0786 in.)

Fig 74: Measuring Plastigage At Widest

Completely remove the Plastigage.

INSPECT CRANKSHAFT BEARING CAP SET BOLT
1. Using vernier calipers, measure the minimum diameter of the compressed thread at the measuring point.
  Standard diameter: 10.76 to 10.97 mm (0.4236 to 0.4319 in.)
  
  Minimum diameter: 10.66 mm (0.4197 in.)
  
  If the diameter is less than the minimum, replace the bolt.
  
  Fig 75: Measuring Minimum Diameter Of Compressed Thread Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT NO.1 BALANCER SHAFT

Inspect the diameter of the journal.

Using a micrometer, measure the diameter of the balancer shaft main journals.

Main journal diameter

MAIN JOURNAL DIAMETER SPECIFICATION

A	37.969 to 37.985 mm (1.4948 to 1.4955 in.)
B	37.449 to 37.465 mm (1.4744 to 1.4750 in.)

Fig 76: Measuring Diameter Of Balancer Shaft Main Journals Using Micrometer

Inspect the diameter of bearing.

Using a cylinder gauge, measure the inside diameter of the balancer shaft bearing.

Bearing inside diameter

BEARING INSIDE DIAMETER SPECIFICATION

A	38.025 to 38.045 mm (1.4970 to 1.4978 in.)
B	37.525 to 37.545 mm (1.4774 to 1.4781 in.)

Fig 77: Measuring Inside Diameter Of Balancer Shaft Bearing Using Cylinder Gauge

Inspect oil clearance.

Subtract the balancer shaft main journal diameter measurement from the balancer shaft bearing inside diameter measurement.

Standard oil clearance

BALANCER SHAFT BEARING SPECIFICATION

A	0.040 to 0.076 mm (0.0016 to 0.0030 in.)
B	0.060 to 0.096 mm (0.0024 to 0.0038 in.)

Maximum oil clearance: 0.15 mm (0.0059 in.)

If the oil clearance is greater than the maximum, replace the cylinder block and balancer shaft.

INSPECT NO.2 BALANCER SHAFT

Inspect the diameter of the journal.

Using a micrometer, measure the diameter of the balancer shaft main journals.

Main journal diameter

MAIN JOURNAL DIAMETER SPECIFICATION

A	37.969 to 37.985 mm (1.4948 to 1.4955 in.)
B	37.449 to 37.465 mm (1.4744 to 1.4750 in.)

Fig 78: Measuring Diameter Of Balancer Shaft Main Journals Using Micrometer

Inspect the diameter of bearing.

Using a cylinder gauge, measure the inside diameter of the balancer shaft bearing.

Bearing inside diameter

BEARING INSIDE DIAMETER SPECIFICATION

A	38.025 to 38.045 mm (1.4970 to 1.4978 in.)
B	37.525 to 37.545 mm (1.4774 to 1.4781 in.)

Fig 79: Measuring Inside Diameter Of Balancer Shaft Bearing Using Cylinder Gauge

Inspect oil clearance.

Standard oil clearance

OIL CLEARANCE SPECIFICATION

A	0.040 to 0.076 mm (0.0016 to 0.0030 in.)
B	0.060 to 0.096 mm (0.0024 to 0.0038 in.)

Maximum oil clearance: 0.15 mm (0.0059 in.)

If the oil clearance is greater than the maximum, replace the cylinder block and balancer shaft.