Engine Unit: Inspection

INSPECT CHAIN TENSIONER ASSEMBLY NO.1
1. Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.
2. Release the ratchet pawl, then check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
  
  Fig 1: Checking Plunger Locked In Place By Ratchet Pawl
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CHAIN SUB-ASSEMBLY
1. Using a spring tension gauge and vernier calipers, pull the timing chain with 140 N (14.3 kgf, 31.5 lb), then measure its length.
  Maximum chain elongation:
  
  115.3 mm (4.539 in.)
  
  If the chain elongation is greater than maximum, replace the chain.
  
  HINT:
  
  Take the same measurements by pulling at 3 or more places selected at random.
  
  Fig 2: Inspecting Chain Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
1. Wrap the chain around the camshaft timing gear.
2. Using vernier calipers, measure the diameter of the timing gear with the chain wrapped.
  Minimum gear diameter (w/ chain):
  
  96.8 mm (3.811 in.)
  
  NOTE: The vernier calipers must be in contact with the chain rollers when measuring.
  
  If the diameter is less than minimum, replace the chain and camshaft timing gear.
  
  Fig 3: Measuring Diameter Of Timing Gear With Chain Wrapped
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
1. Wrap the chain around the crankshaft timing gear.
2. Using vernier calipers, measure the crankshaft timing gear diameter with the chain.
  Minimum gear diameter (w/ chain):
  
  51.0 mm (2.008 in.)
  
  NOTE: The vernier calipers must be in contact with the chain rollers when measuring.
  
  If the diameter is less than minimum, replace the chain and crankshaft timing gear.
  
  Fig 4: Inspecting Crankshaft Timing Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CHAIN TENSIONER SLIPPER
1. Using verniers calipers, measure the chain tensioner slipper wear.
  Maximum wear:
  
  1.0 mm (0.039 in.)
  
  If the wear is greater than maximum, replace the chain tensioner slipper.
  
  Fig 5: Measuring Chain Tensioner Slipper Wear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CHAIN VIBRATION DAMPER NO.1
1. Using vernier calipers, measure the vibration damper wears.
  Maximum wear:
  
  1.0 mm (0.039 in.)
  
  If the wear is greater than maximum, replace the chain vibration damper.
  
  Fig 6: Measuring Vibration Damper Wears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER HEAD SET BOLT
1. Using vernier calipers, measure the length of the cylinder head bolts from the seat to the end.
  Standard bolt length:
  
  146.8 to 148.2 mm (5.780 to 5.835 in.)
  
  Maximum bolt length:
  
  148.5 mm (5.846 in.)
  
  If the bolt length is greater than maximum, replace the cylinder head set bolt.
  
  Fig 7: Inspecting Cylinder Head Set Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CAMSHAFT
1. 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 maximum, replace the camshaft.
    
    Fig 8: Inspecting Camshaft
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect the cam lobes.
  1. Using a micrometer, measure the cam lobe height.
    Standard cam lobe height:
    
    Intake:
    
    44.333 to 44.433 mm (1.7454 to 1.7493 in.)
    
    Exhaust:
    
    43.761 to 43.861 mm (1.7229 to 1.7268 in.)
    
    Minimum cam lobe height:
    
    Intake:
    
    44.18 mm (1.7394 in.)
    
    Exhaust:
    
    43.61 mm (1.7169 in.)
    
    Fig 9: Measuring Cam Lobe Height
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the cam lobe height is less than minimum, replace the camshaft.
3. Inspect the camshaft journals.
  1. Using a micrometer, measure the journal diameter.
    No. 1 journal diameter:
    
    34.449 to 34.465 mm (1.3563 to 1.3569 in.)
    
    Other journal diameters:
    
    22.949 to 22.965 mm (0.9035 to 0.9041 in.)
    
    If the journal diameter is not as specified, check the oil clearance.
    
    Fig 10: Measuring Journal Diameter Using Micrometer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK CYLINDER BLOCK FOR FLATNESS
1. Using a precision straight edge and feeler gauge, measure the warpage on the surface that is in contact with the cylinder head gasket.
  Maximum warpage:
  
  0.05 mm (0.0020 in.)
  
  If the warpage is greater than maximum, replace the cylinder block.
  
  Fig 11: Checking Cylinder Block For Flatness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER BORE
1. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
  Standard diameter:
  
  79.000 to 79.013 mm (3.1102 to 3.1107 in.)
  
  Maximum diameter:
  
  79.133 mm (3.1155 in.)
  
  If the average diameter of 4 positions is greater than maximum, replace the cylinder block.
  
  Fig 12: Measuring Cylinder Bore Diameter At Positions A And B In Thrust And Axial Directions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT W/PIN PISTON SUB-ASSEMBLY
1. Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at a piston of 28.0 mm (1.102 in.) from the top the piston head.
  Piston diameter:
  
  78.917 to 78.927 mm (3.1070 to 3.1074 in.)
  
  If the diameter is not as specified, replace the piston assembly.
  
  Fig 13: Measuring Piston Diameter At Right Angles To Piston Pin Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK PISTON OIL CLEARANCE
1. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
  Standard oil clearance:
  
  0.073 to 0.096 mm (0.0029 to 0.0038 in.)
  
  Maximum oil clearance:
  
  0.10 mm (0.0039 in.)
  - If the oil clearance is greater than maximum, replace all pistons.
  - If necessary, replace the cylinder block.

CHECK PISTON PIN OIL CLEARANCE

Using a caliper gauge, measure the piston pin bore diameter.

Piston pin bore diameter:

20.006 to 20.015 mm (0.7876 to 0.7880 in.)

PISTON PIN DIAMETER REFERENCE CHART

Mark	mm (in.)
A	20.006 to 20.009 (0.7876 to 0.7878)
B	20.010 to 20.012 (0.7878 to 0.7879)
C	20.013 to 20.015 (0.7879 to 0.7880)

If the bore diameter is not as specified, replace the piston assembly.

Fig 14: Measuring Inside Diameter Of Piston Pin Hole

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the piston pin outer diameter.

Piston pin outer diameter:

20.004 to 20.013 mm (0.7876 to 0.7879 in.)

PISTON PIN DIAMETER REFERENCE CHART

Mark	mm (in.)
A	20.004 to 20.007 (0.7876 to 0.7877)
B	20.008 to 20.010 (0.7877 to 0.7878)
C	20.011 to 20.013 (0.7878 to 0.7879)

If the outer diameter is not as specified, replace the piston assembly.

Fig 15: Measuring Piston Pin Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a caliper gauge, measure the connecting rod small end bore diameter.

Connecting rod small end bore diameter:

20.012 to 20.021 mm (0.7879 to 0.7882 in.)

CONNECTING ROD DIAMETER REFERENCE CHART

Mark	mm (in.)
A	20.012 to 20.015 (0.7879 to 0.7880)
B	20.016 to 20.018 (0.7880 to 0.7881)
C	20.019 to 20.021 (0.7881 to 0.7882)

If the diameter is not as specified, replace the connecting rod assembly.

Fig 16: Measuring Connecting Rod Small End Bore Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Subtract the piston pin outer diameter measurement from the piston pin bore diameter measurement.
Standard oil clearance:

0.002 to 0.011 mm (0.0001 to 0.0004 in.)

Maximum oil clearance:

0.011 mm (0.0004 in.)
- If the oil clearance is greater than maximum, replace the connecting rod assembly.
- If necessary, replace the piston assembly.
Subtract the piston pin outer diameter measurement from the connecting rod small end bore diameter measurement.
Standard oil clearance:

-0.001 to 0.017 mm (-0.00004 to 0.0007 in.)

Maximum oil clearance:

0.017 mm (0.0007 in.)
- If the oil clearance is greater than maximum, replace the connecting rod assembly.
- If necessary, replace both the connecting rod assembly and piston assembly.

CHECK RING GROOVE CLEARANCE

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

Ring groove clearance

RING GROOVE CLEARANCE SPECIFICATION

Item	Specification
No. 1 ring	0.02 to 0.07 mm (0.0008 to 0.0028 in.)
No. 2 ring	0.03 to 0.07 mm (0.0012 to 0.0028 in.)
Oil ring	0.03 to 0.11 mm (0.0012 to 0.0043 in.)

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

Fig 18: Inspecting Ring Groove Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

CHECK PISTON RING END GAP

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 19: Positioning Piston Ring On Top Of Cylinder Block
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a feeler gauge, measure the end gap.

Standard end gap

END GAP SPECIFICATION

Item	Specification
No. 1 ring	0.25 to 0.35 mm (0.0098 to 0.0138 in.)
No. 2 ring	0.35 to 0.50 mm (0.0138 to 0.0197 in.)
Oil ring	0.15 to 0.40 mm (0.0059 to 0.0157 in.)

Maximum end gap

END GAP SPECIFICATION

Item	Specification
No. 1 ring	1.05 mm (0.0413 in.)
No. 2 ring	1.20 mm (0.0472 in.)

If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block.

Fig 20: Measuring End Gap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CONNECTING ROD SUB-ASSEMBLY
1. Using a connecting rod aligner and feeler gauge, check the connecting rod alignment.
  1. Check for misalignment.
    Maximum misalignment:
    
    0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
    
    If the misalignment is greater than maximum, replace the connecting rod assembly.
    
    Fig 21: Checking Connecting Rod Alignment Using Connecting Rod Aligner And Feeler Gauge
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check for twist.
    Maximum twist:
    
    0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
    
    If the twist is greater than maximum, replace the connecting rod assembly.
    
    Fig 22: Checking For Twist
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CONNECTING ROD BOLT
1. Using vernier calipers, measure the tension portion diameter of the bolts.
  Standard diameter:
  
  6.6 to 6.7 mm (0.260 to 0.264 in.)
  
  Minimum diameter:
  
  6.4 mm (0.252 in.)
  
  If the diameter is less than minimum, replace the connecting rod bolt.
  
  Fig 23: Measuring Diameter Of Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT
1. Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration.
  Maximum circle runout:
  
  0.03 mm (0.0012 in.)
  
  If the circle runout is greater than maximum, replace the crankshaft.
  
  Fig 24: Measuring Circle Runout Using Dial Indicator And V-Blocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the diameter of each main journal at the points shown in the illustration.
  Diameter:
  
  47.988 to 48.000 mm (1.8893 to 1.8898 in.)
  
  If the diameter is not as specified, check the crankshaft oil clearance.
  
  Fig 25: Measuring Diameter Of Each Main Journal At Points
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check each main journal for taper and distortion as shown.
  Maximum taper and distortion:
  
  0.02 mm (0.0008 in.)
  
  If the taper and distortion are greater than maximum, replace the crankshaft.
4. Using a micrometer, measure the diameter of each crank pin at the points shown in the illustration.
  Diameter:
  
  43.992 to 44.000 mm (1.7320 to 1.7323 in.)
  
  If the diameter is not as specified, check the connecting rod oil clearance.
5. Check each crank pin for taper and distortion.
  Maximum taper and distortion:
  
  0.02 mm (0.0008 in.)
  
  If the taper and distortion are greater than maximum, replace the crankshaft.
  
  Fig 26: Identifying Crank Pin Out-Of-Round
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT BEARING CAP SET BOLT
1. Using vernier calipers, measure the tension portion diameter of the bolts.
  Standard diameter:
  
  7.3 to 7.5 mm (0.287 to 0.295 in.)
  
  Minimum diameter:
  
  7.3 mm (0.287 in.)
  
  If the diameter is less than minimum, replace the crankshaft bearing cap set bolt.
  
  Fig 27: Measuring Tension Portion Diameter Of Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

CHECK CRANKSHAFT OIL CLEARANCE

NOTE: Do not turn the crankshaft.

Clean each main journal and bearing.
Place the crankshaft on the cylinder block.
Lay a strip of the Plastigage across each journal.

Fig 28: Laying Strip Of Plastigage Across Each Journal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST, tighten the bolts to the specified torque in the several passes in the sequence shown.
Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf)

Fig 29: Identifying Cylinder Head Bolt Tighten Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Mark the front of the bearing cap bolts with paint.
Retighten the bearing cap bolts by 90° as shown in the illustration.
Check that the painted mark of each bolt is now at a 90° angle to the front.

Fig 30: Checking Paint Mark On Connecting Rod Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Tighten the 10 other bolts for the bearing cap.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
Uniformly loosen the 10 bearing cap bolts in several passes in the sequence shown in the illustration.

Fig 32: Identifying Bearing Cap Bolt Loosen Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Measure the Plastigage at its widest point.

Standard oil clearance:

0.015 to 0.032 mm (0.0006 to 0.0013 in.)

Maximum oil clearance:

0.05 mm (0.0020 in.)

Fig 33: Measuring Plastigage Widest Point

NOTE: Completely remove the Plastigage.

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

HINT:

If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft, then select a new bearing with the calculated number. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.

BEARING SPECIFICATION

Cylinder block (A) + Crankshaft (B)	0 to 2	3 to 5	6 to 8	9 to 11
Use bearing	"1"	"2"	"3"	"4"

EXAMPLE:

Cylinder block "3" (A) + Crankshaft "4" (B) = Total number 7 (Use bearing "3")

BEARING SPECIFICATION

Item	Mark	mm (in.)
Cylinder block journal bore diameter (A)	"0"	52.000 to 52.002 (2.0472 to 2.0473)
	"1"	52.003 to 52.004 (2.0474 to 2.0474)
	"2"	52.005 to 52.006 (2.0474 to 2.0475)
	"3"	52.007 to 52.009 (2.0475 to 2.0476)
	"4"	52.010 to 52.011 (2.0476 to 2.0477)
	"5"	52.012 to 52.013 (2.0477 to 2.0478)
	"6"	52.014 to 52.015 (2.0478 to 2.0478)
Crankshaft journal diameter (B)	"0"	47.999 to 48.000 (1.8897 to 1.8898)
	"1"	47.997 to 47.998 (1.8896 to 1.8897)
	"2"	47.995 to 47.996 (1.8896 to 1.8896)
	"3"	47.993 to 47.994 (1.8895 to 1.8895)
	"4"	47.991 to 47.992 (1.8894 to 1.8894)
	"5"	47.988 to 47.990 (1.8893 to 1.8894)
Standard bearing center wall thickness	"1"	1.994 to 1.997 (0.0785 to 0.0786)
	"2"	1.998 to 2.000 (0.0787 to 0.0787)
	"3"	2.001 to 2.003 (0.0788 to 0.0789)
	"4"	2.004 to 2.006 (0.0789 to 0.0790)