Engine Unit: Inspection: Inspection

INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Turn the roller by hand and check that it turns smoothly.
  If the roller does not turn smoothly, replace the valve rocker arm sub-assembly.

INSPECT VALVE LASH ADJUSTER ASSEMBLY

NOTE:

Keep the adjuster free from dirt and foreign matter.
Use only clean engine oil.

Place the lash adjuster into a container full of new engine oil.

Fig 1: Inspecting Valve Lash Adjuster Assembly Using SST

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Taper 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.

NOTE:
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.

INSPECT CAMSHAFT OIL CLEARANCE

NOTE:

Do not turn the camshafts.

Clean the bearing caps, camshaft housing and camshaft journals.
Place the camshafts on the camshaft housing.
Lay a strip of Plastigage across each of the camshaft journals.

Fig 2: Inspecting Camshaft Oil Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION

*1 Plastigage
Install the camshaft bearing caps See step 11.
Install the camshaft housing sub-assembly See step 12.
Remove the camshaft bearing caps See step 20.

Measure the Plastigage at its widest point.

Fig 3: Measuring The Plastigage

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard Oil Clearance

Item	Specified Condition
Intake No. 1 journal	0.035 to 0.072 mm (0.00137 to 0.00283 in.)
Exhaust No. 1 journal	0.049 to 0.086 mm (0.00193 to 0.00339 in.)
Other journals	0.025 to 0.062 mm (0.00098 to 0.00244 in.)

Maximum Oil Clearance

Item	Specified Condition
Intake No. 1 journal	0.085 mm (0.00335 in.)
Exhaust No. 1 journal	0.095 mm (0.00374 in.)
Other journals	0.085 mm (0.00335 in.)

TEXT IN ILLUSTRATION

*1	Plastigage
*2	No. 1 Journal
*3	Other Journals

If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the camshaft housing.

INSPECT CAMSHAFT THRUST CLEARANCE See step 8

INSPECT CAMSHAFT

Inspect 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 sub-assembly.
  
  HINT:
  
  Check the oil clearance after replacing the camshaft.

Inspect the cam lobes.

Using a micrometer, measure the cam lobe height.

Standard Cam Lobe Height

Item	Specified Condition
Intake	44.163 to 44.305 mm (1.739 to 1.744 in.)
Exhaust	44.144 to 44.286 mm (1.738 to 1.744 in.)

Minimum Cam Lobe Height

Item	Specified Condition
Intake	44.013 mm (1.733 in.)
Exhaust	43.996 mm (1.732 in.)

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

Inspect the camshaft journals.

Using a micrometer, measure the journal diameter.

Standard Journal Diameter

Item	Specified Condition
No. 1 journal	34.449 to 34.465 mm (1.356 to 1.357 in.)
Other journals	22.959 to 22.975 mm (0.904 to 0.905 in.)

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

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

Align the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear and attach the gear to the camshaft.

Fig 4: Aligning No. 1 Camshaft Knock Pin & Timing Gear Pin Hole

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Pin Hole
*2	Knock Pin

Check that there is no clearance between the camshaft timing gear and camshaft flange.

Fig 5: Checking Clearance Between Camshaft Timing Gear & Flange

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Camshaft Timing Gear
*2	Clearance
*3	Flange
*4	No Clearance
*a	INCORRECT
*b	CORRECT

Fix the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.
NOTE:
Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.
Check the lock of the camshaft timing gear.
1. Make sure that the camshaft timing gear is locked.
  NOTE:
  Be careful not to damage the camshaft.

Release the lock pin.

Clean the camshaft journal with non-residue solvent.

Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

Fig 6: Camshaft Journal Oil Paths

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Retard Side Path
*2	Advance Side Path
*3	Port A
*4	Knock Pin
*a	Open
*b	Closed
	Rubber
	Vinyl Tape

HINT:

There are 4 oil paths in the grooves of the camshaft. Plug three of the paths with pieces of rubber.

Open a hole at port A shown in the illustration.
While applying compressed air at approximately 200 kPa (2.0 kgf/ cm² , 29 psi) to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

Fig 7: Turning Camshaft Timing Gear Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WARNING:
Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.

NOTE:
Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

HINT:
- The camshaft timing gear assembly may be turned in the advance direction without applying any force.
- If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

Check for smooth rotation.
1. Turn the camshaft timing gear within its movable range (26.5 to 28.5°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.
  NOTE:
  Do not allow the camshaft timing gear assembly to lock.
  
  If it locks, release the lock pin again.
Remove the vinyl tape and pieces of rubber from the camshaft.
Remove the bolt and camshaft timing gear.

INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

Align the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear and attach the gear to the camshaft.

Fig 8: Aligning No. 2 Camshaft Knock Pin & Timing Gear Pin Hole

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Pin Hole
*2	Knock Pin

Check that there is no clearance between the camshaft timing exhaust gear and camshaft flange.

Fig 9: Checking Clearance Between Camshaft Timing Gear & Flange

TEXT IN ILLUSTRATION

*1	Camshaft Timing Exhaust Gear
*2	Clearance
*3	Flange
*4	No Clearance
*a	INCORRECT
*b	CORRECT

Fix the camshaft in place by hand, and then install the installation bolt of the camshaft timing exhaust gear by hand.
Check the lock of the camshaft timing exhaust gear.
1. Make sure that the camshaft timing exhaust gear is locked.
  NOTE:
  Be careful not to damage the camshaft.

Release the lock pin.

Clean the camshaft journal with non-residue solvent.

Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

Fig 10: Camshaft Journal Oil Paths

TEXT IN ILLUSTRATION

*1	Advance Side Path
*2	Retard Side Path
*3	Knock Pin
*a	Open
*b	Closed
	Rubber
	Vinyl Tape

HINT:

There are 4 oil paths in the grooves of the camshaft. Plug 2 paths with pieces of rubber.

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.

Apply compressed air at approximately 200 kPa (2.0 kgf/cm² , 29 psi) to the two open paths (the advance side path and retard side path).

Fig 11: Applying Compressed Air To Camshaft Journal Oil Paths

TEXT IN ILLUSTRATION

*1	Retard Side Path
*2	Advance Side Path

NOTE:

Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.

Check that the camshaft timing exhaust gear turns in the retard direction when reducing the air pressure applied to the advance side path.

Fig 12: Checking Camshaft Timing Exhaust Gear Turns In Retard Direction

TEXT IN ILLUSTRATION

*1	Retard Side Path
*2	Advance Side Path
*3	Hold Pressure
*4	Decompress

HINT:

The lock pin is released and the camshaft timing exhaust gear turns in the retard direction.

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.
NOTE:
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.

Check for smooth rotation.
1. Turn the camshaft timing exhaust gear within its movable range (21.5 to 23.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.
  NOTE:
  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.
Check the lock at the most advanced position.
1. Make sure that the camshaft timing exhaust gear locks at the most advanced position.
Remove the vinyl tape and pieces of rubber from the camshaft.
Remove the bolt and camshaft timing gear.

INSPECT CHAIN SUB-ASSEMBLY

Fig 13: Pulling Chain Using Spring Scale
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.
2. Using a vernier caliper, measure the length of 15 pins.
  Maximum chain elongation
  
  137.7 mm (5.42 in.)
  TEXT IN ILLUSTRATION
  
  *1 Measuring Area
  
  HINT:
  
  Perform the measurement at 3 random places.
  
  If the elongation is more than the maximum, replace the chain sub-assembly.
INSPECT CRANKSHAFT TIMING SPROCKET
1. Wrap the chain around the sprocket.
  
  Fig 14: Measuring Sprocket Diameter With Chain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a vernier caliper, measure the sprocket diameter together with the chain.
  Minimum sprocket diameter (with chain)
  
  59.94 mm (2.36 in.)
  
  If the diameter is less than the minimum, replace the chain and crankshaft timing sprocket.
  
  HINT:
  
  The vernier caliper must contact the chain rollers for the measurement.
INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY
1. Move the stopper plate counterclockwise to release the lock. Push the plunger and check that it moves smoothly.
  
  Fig 15: Inspecting No. 1 Chain Tensioner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If necessary, replace the No. 1 chain tensioner assembly.
INSPECT CHAIN TENSIONER SLIPPER
1. Measure the depth of wear of the chain tensioner slipper.
  
  Fig 16: Measuring Chain Tensioner Slipper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum depth
  
  1.0 mm (0.0394 in.)
  TEXT IN ILLUSTRATION
  
  *1 Depth
  
  If the depth is more than the maximum, replace the chain tensioner slipper.
INSPECT NO. 1 CHAIN VIBRATION DAMPER
1. Measure the depth of wear of the chain vibration damper.
  
  Fig 17: Measuring Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum depth
  
  1.0 mm (0.0394 in.)
  TEXT IN ILLUSTRATION
  
  *1 Depth
  
  If the depth is more than the maximum, replace the No. 1 chain vibration damper.
INSPECT TIMING CHAIN GUIDE
1. Measure the depth of wear of the timing chain guide.
  
  Fig 18: Measuring Timing Chain Guide
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum depth
  
  1.0 mm (0.0394 in.)
  TEXT IN ILLUSTRATION
  
  *1 Depth
  
  If the depth is more than the maximum, replace the timing chain guide.
INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.
  
  Fig 19: Inspecting No. 1 Balance Shaft Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard thrust clearance
  
  0.05 to 0.09 mm (0.00197 to 0.00354 in.)
  
  Maximum thrust clearance
  
  0.09 mm (0.00354 in.)
  
  If the thrust clearance is more than the maximum, replace the engine balancer assembly.
INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the No. 2 balance shaft back and forth.
  
  Fig 20: Inspecting No. 2 Balance Shaft Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard thrust clearance
  
  0.05 to 0.09 mm (0.00197 to 0.00354 in.)
  
  Maximum thrust clearance
  
  0.09 mm (0.00354 in.)
  
  If the thrust clearance is more than the maximum, replace the engine balancer assembly.
INSPECT BALANCE SHAFT BACKLASH
1. Fix the No. 2 balance shaft in place, and then, using a dial indicator, measure the backlash of the No. 1 and No. 2 balance shafts as shown in the illustration.
  
  Fig 21: Measuring No. 1 And No. 2 Balance Shafts Backlash
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard backlash
  
  0.04 to 0.17 mm (0.00154 to 0.00669 in.)
  
  Maximum backlash
  
  0.17 mm (0.00669 in.)
  TEXT IN ILLUSTRATION
  
  *a Fix in place
  
  NOTE:
  Measure at 3 or more areas around the circumference of the No. 1 and No. 2 balance shafts.
  
  If the backlash is more than the maximum, replace the engine balancer assembly.
INSPECT CYLINDER HEAD BOLT
1. Using a vernier caliper, measure the diameter of the elongated thread at the measuring point.
  
  Fig 22: Measuring Cylinder Head Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Measuring point
  
  106 mm (4.17 in.)
  
  Standard diameter
  
  10.85 to 11.00 mm (0.427 to 0.433 in.)
  
  Minimum diameter
  
  10.6 mm (0.417 in.)
  TEXT IN ILLUSTRATION
  
  *1 Measuring Point
  
  If the diameter is less than the minimum, replace the cylinder head bolt.
  
  HINT:
  
  If a visual check reveals no excessively thin areas, check the center of the bolt (see illustration Fig 22) and find the area that has the smallest diameter.
INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
1. Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts the cylinder head.
  
  Fig 23: Checking Exhaust Manifold Converter Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum warpage
  
  0.7 mm (0.0276 in.)
  
  If the warpage is more than the maximum, replace the exhaust manifold.