Engine Unit: Inspection: Inspection

WARNING: This page is about a different car, the 2011 Toyota Avalon. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT VALVE LASH ADJUSTER ASSEMBLY
NOTE:
- Keep the lash adjuster free from dirt and foreign objects.
- Only use clean engine oil.
1. Place the valve lash adjuster assembly into a container filled with engine oil.
  
  Fig 1: Checking Movement Of Plunger Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Insert the SST tip into the valve lash adjuster assembly plunger and use the tip to press down on the check ball inside the plunger.
  - SST: 09276-75010
3. Squeeze SST and the valve lash adjuster assembly 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 air from the high-pressure 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.
5. After bleeding the air, remove SST. Then try to 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.

INSPECT CAMSHAFTS

Inspect the camshaft for runout.

Fig 2: Measuring Circle Runout At Center Journal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Place the camshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
  Maximum circle runout
  
  0.04 mm (0.0016 in.)
  
  If the circle runout is greater than the maximum, replace the camshaft.
  
  HINT:
  
  Check the oil clearance after replacing the camshaft.

Using a micrometer, measure the cam lobe height.

Fig 3: Measuring Cam Lobe Height

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard cam lobe height

Item	Specification
Intake	44.316 to 44.416 mm (1.7447 to 1.7487 in.)
Exhaust	44.262 to 44.362 mm (1.7426 to 1.7465 in.)

Maximum cam lobe height

Item	Specification
Intake	44.166 mm (1.7388 in.)
Exhaust	44.112 mm (1.7367 in.)

Using a micrometer, measure the journal diameter.

Fig 4: Measuring Journal Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard journal diameter

Item	Specification
No. 1 journal	35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journal	25.959 to 25.975 mm (1.0220 to 1.0226 in.)

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

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
1. Clamp the camshaft in a vise.
  NOTE:
  Be careful not to damage the camshaft in the vise.
2. Put the camshaft timing gear and camshaft together by aligning the key groove and straight pin.
  
  Fig 5: Aligning Key Groove And Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.
  WARNING:
  Be sure not to turn the camshaft timing gear in the retard direction (the right angle).
4. Check that there is no clearance between the gear's fringe and the camshaft.
5. Tighten the fringe bolt with the camshaft timing gear fixed.
  
  Fig 6: Tightening Fringe Bolt With Camshaft Timing Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
6. Check the lock of the camshaft timing gear.
  1. Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked.
    NOTE:
    Be careful not to damage the camshaft.
7. Release the lock pin.
  
  Fig 7: Covering Oil Paths Of Cam Journal With Vinyl Tape
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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/cm² , 28 psi) of air pressure to the two broken paths.
    
    Fig 8: Applying Air Pressure To Two Broken Paths
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    WARNING:
    Cover the paths with a shop rag or piece of cloth when applying pressure to keep oil from splashing.
  4. Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path.
    
    Fig 9: Checking Camshaft Timing Gear Revolves In Advance Direction
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    HINT:
    
    This operation releases the lock pin for the most retarded position.
  5. When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path, in that order.
    NOTE:
    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.
8. Check for smooth rotation.
  1. Turn the camshaft timing gear 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.
    WARNING:
    Do not use air pressure to perform the smooth operation check.
9. Check the lock in the most retarded position.
  1. Confirm that the camshaft timing gear is locked at the most retarded position.
10. Remove the fringe bolt and camshaft timing gear.
  
  Fig 10: Identifying Fringe Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be sure not to remove the other 3 bolts.
  - If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.
INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY LH
1. Clamp the camshaft in a vise.
  NOTE:
  Be careful not to damage the camshaft in the vise.
2. Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and straight pin.
  
  Fig 11: Aligning Key Groove And Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.
  WARNING:
  Be sure not to turn the camshaft timing exhaust gear in the retard direction (the right angle).
4. Check that there is no clearance between the gear's fringe and the camshaft.
5. Tighten the fringe bolt with the camshaft timing exhaust gear fixed.
  
  Fig 12: Tightening Fringe Bolt With Camshaft Timing Exhaust Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
6. Check the camshaft timing exhaust gear lock.
  1. Make sure that the camshaft timing exhaust gear is locked.
7. Release the lock pin.
  
  Fig 13: Covering Oil Paths Of Cam Journal With Vinyl Tape
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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/cm² , 28 psi) of air pressure to the two broken paths (the advance side path and the retard side path).
    
    Fig 14: Applying Air Pressure To Broken Paths
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    NOTE:
    Cover the paths with a shop rag or 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.
    
    Fig 15: Applying Air Pressure To Two Broken Paths
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    HINT:
    
    The lock pin is released and the camshaft timing exhaust gear turns in the retard direction.
  5. When the camshaft timing exhaust gear comes 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.
8. 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.
    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.
9. Check the lock at the most advanced position.
  1. Make sure that the camshaft timing exhaust gear is locked at the most advanced position.
10. Remove the fringe bolt and camshaft timing exhaust gear.
  
  Fig 16: Identifying Fringe Bolt And Camshaft Timing Exhaust Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - 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.
INSPECT CYLINDER HEAD SET BOLT
1. Using a vernier caliper, measure the minimum diameter of the elongated thread at the measuring point.
  
  Fig 17: Measuring Cylinder Head Bolt Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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 to the area that has the lowest diameter.
  - If the diameter is less than the minimum, replace the cylinder head bolt.
INSPECT CHAIN SUB-ASSEMBLY
1. Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.
  
  Fig 18: Measuring Chain Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a vernier caliper, measure the length of 15 links.
  Maximum chain elongation
  
  136.9 mm (5.390 in.)
  
  NOTE:
  Perform the measurement at 3 random places. Use the average of the measurements.
  
  If the elongation is greater than the maximum, replace the chain.
INSPECT NO. 2 CHAIN SUB-ASSEMBLY
1. Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.
  
  Fig 19: Measuring No. 2 Chain Sub-Assembly Links Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a vernier caliper, measure the length of 15 links.
  Maximum chain elongation
  
  137.6 mm (5.417 in.)
  
  NOTE:
  Perform the measurement at 3 random places. Use the average of the measurements.
  
  If the elongation is greater than the maximum, replace the chain.
INSPECT CRANKSHAFT TIMING GEAR
1. Wrap the chain around the sprocket.
  
  Fig 20: Measuring Sprocket Diameter With Chain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a vernier caliper, measure the sprocket diameter with the chain.
  Minimum sprocket diameter (with chain)
  
  61.4 mm (2.417 in.)
  
  HINT:
  
  The vernier caliper must contact the chain rollers for the measurement.
  
  If the elongation is greater than the maximum, replace the chain.
INSPECT IDLE SPROCKET ASSEMBLY
1. Wrap the chain around the sprocket.
  
  Fig 21: Measuring Sprocket Diameter With Chain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a vernier caliper, measure the sprocket diameter with the chain.
  Minimum sprocket diameter (with chain)
  
  61.4 mm (2.417 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 sprocket.
INSPECT IDLE GEAR SHAFT OIL CLEARANCE
1. Using a micrometer, measure the idle gear shaft diameter.
  
  Fig 22: Measuring Idle Gear Shaft Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Idle gear shaft diameter
  
  22.987 to 23.000 mm (0.9050 to 0.9055 in.)
2. Using a caliper gauge, measure the inside diameter of the idle sprocket.
  
  Fig 23: Measuring Inside Diameter Of Idle Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Idle gear inside diameter
  
  23.020 to 23.030 mm (0.9063 to 0.9067 in.)
3. 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.
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. If necessary, replace the No. 1 chain tensioner assembly.
  
  Fig 24: Moving Stopper Plate Upward To Release Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If necessary, replace the No. 1 chain tensioner assembly.
INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
1. Check that the plunger moves smoothly.
  
  Fig 25: Measuring Worn Depth Of Chain Tensioner Slipper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. 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.
INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY
1. Check that the plunger moves smoothly.
  
  Fig 26: Measuring Worn Depth Of Chain Tensioner Slipper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. 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.
INSPECT CHAIN TENSIONER SLIPPER
1. Measure the worn depth of the chain tensioner slipper.
  
  Fig 27: Measuring Worn Depth Of Chain Tensioner Slipper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum depth
  
  1.0 mm (0.039 in.)
  
  If the depth is greater than the maximum, replace the chain tensioner slipper.
INSPECT NO. 1 CHAIN VIBRATION DAMPER
1. Measure the worn depth of the No. 1 chain vibration damper.
  
  Fig 28: Measuring Worn Depth Of The No. 1 Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum depth
  
  1.0 mm (0.039 in.)
  
  If the depth is greater than the maximum, replace the No. 1 chain vibration damper.
INSPECT NO. 2 CHAIN VIBRATION DAMPER
1. Measure the worn depth of the No. 2 chain vibration damper.
  
  Fig 29: Measuring Worn Depth Of Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum depth
  
  1.0 mm (0.039 in.)
  
  If the depth is greater than the maximum, replace the No. 2 chain vibration damper.

INSPECT CYLINDER HEAD SUB-ASSEMBLY

Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder block and manifolds.

Fig 30: Measuring Warpage Of Contact Surface Of Cylinder Block And Manifolds

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard warpage

Item	Warpage
Cylinder head lower	0.05 mm (0.0020 in.)
Intake	0.08 mm (0.0031 in.)
Exhaust	0.08 mm (0.0031 in.)

Maximum warpage

0.10 mm (0.0039 in.)

If the warpage is greater than the maximum, replace the cylinder head assembly.

Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head assembly.

Fig 31: Checking Intake Ports, Exhaust Ports And Cylinder Surface For Cracks
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT INTAKE VALVE
1. Using a micrometer, measure the diameter of the valve stem.
  
  Fig 32: Measuring Diameter Of Valve Stem
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Valve stem diameter
  
  5.470 to 5.485 mm (0.2154 to 0.2159 in.)
  
  If the valve stem is not as specified, check the oil clearance.
2. Using a vernier caliper, measure the valve head margin thickness.
  
  Fig 33: Identifying Valve Head Margin Thickness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard margin thickness
  
  1.0 mm (0.0394 in.)
  
  Minimum margin thickness
  
  0.5 mm (0.0197 in.)
  
  If the margin thickness is less than the minimum, replace the intake valve.
3. Using a vernier caliper, measure the valve's overall length.
  
  Fig 34: Measuring Valve's Overall Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard overall length
  
  105.85 mm (4.1673 in.)
  
  Minimum overall length
  
  105.35 mm (4.1476 in.)
  
  If the overall length is less than the minimum, replace the intake valve.
INSPECT EXHAUST VALVE
1. Using a micrometer, measure the diameter of the valve stem.
  
  Fig 35: Measuring Diameter Of Valve Stem
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Valve stem diameter
  
  5.465 to 5.480 mm (0.2151 to 0.2157 in.)
  
  If the valve stem is not as specified, check the oil clearance.
2. Using a vernier caliper, measure the valve head margin thickness.
  
  Fig 36: Measuring Valve Head Margin Thickness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard margin thickness
  
  1.0 mm (0.0394 in.)
  
  Minimum margin thickness
  
  0.5 mm (0.0197 in.)
  
  If the margin thickness is less than the minimum, replace the exhaust valve.
3. Using a vernier caliper measure the valve's overall length.
  
  Fig 37: Measuring Valve's Overall Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard overall length
  
  110.40 mm (4.3464 in.)
  
  Minimum overall length
  
  109.90 mm (4.3268 in.)
  
  If the overall length is less than the minimum, replace the exhaust valve.
INSPECT INTAKE VALVE SEATS
1. Apply a light coat of prussian blue to the valve face.
  
  Fig 38: Checking Valve Face And Valve Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 1.1 and 1.6 mm (0.043 and 0.063 in.).
INSPECT EXHAUST VALVE SEATS
1. Apply a light coat of prussian blue to the valve face.
  
  Fig 39: Checking Valve Face And Valve Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 1.1 and 1.6 mm (0.043 and 0.063 in.).
REPAIR INTAKE VALVE SEATS
NOTE:
Keep the lip free from foreign matter.
1. If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.
  
  Fig 40: Identifying Valve Face Angle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.
  
  Fig 41: Identifying Valve Face Angle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Handrub the valve and valve seat with an abrasive compound.
4. Check the valve seating position.
REPAIR EXHAUST VALVE SEATS
NOTE:
Keep the lip free from foreign matter.
1. If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.
  
  Fig 42: Identifying Valve Face Angle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. If the seating is too low on the valve face, use 45° and 75° cutters to correct the seat.
  
  Fig 43: Identifying Valve Face Angle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Handrub the valve and valve seat with an abrasive compound.
4. Check the valve seating position.
INSPECT INNER COMPRESSION SPRING
1. Using a vernier caliper, measure the free length of the inner compression spring.
  
  Fig 44: Measuring Free Length Of Inner Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Free length
  
  45.91 mm (1.8075 in.)
  
  If the free length is not as specified, replace the spring.
2. Using a steel square, measure the deviation of the inner compression spring.
  
  Fig 45: Measuring Deviation Of Inner Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum deviation
  
  1.0 mm (0.039 in.)
  
  Maximum angle (reference)
  
  2°
  
  If the deviation is greater than the maximum, replace the spring.

INSPECT VALVE GUIDE BUSH OIL CLEARANCE

Using a caliper gauge, measure the inside diameter of the valve guide bush.

Fig 46: Measuring Inside Diameter Of Guide Bush Using Caliper Gauge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bush inside diameter

5.510 to 5.530 mm (0.2169 to 0.2177 in.)

Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.

Standard clearance

Item	Clearance
Intake	0.025 to 0.060 mm (0.0010 to 0.0024 in.)
Exhaust	0.030 to 0.065 mm (0.0012 to 0.0026 in.)

Maximum oil clearance

Item	Clearance
Intake	0.08 mm (0.0032 in.)
Exhaust	0.10 mm (0.0039 in.)

For intake side

If the clearance is greater than the maximum, replace the intake valve and intake valve guide bush.

For exhaust side

If the clearance is greater than the maximum, replace the exhaust valve and exhaust valve guide bush.

INSPECT CAMSHAFT THRUST CLEARANCE
1. Install the bank 1 camshaft Refer to step 29.
  
  Fig 47: Measuring Camshaft Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
  Standard thrust clearance
  
  0.08 to 0.13 mm (0.0031 to 0.0051 in.)
  
  Maximum thrust clearance
  
  0.15 mm (0.006 in.)
  
  If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.
3. Install the bank 2 camshaft Refer to step 31.
4. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
  Standard thrust clearance
  
  0.08 to 0.13 mm (0.0031 to 0.0051 in.)
  
  Maximum thrust clearance
  
  0.15 mm (0.006 in.)
  
  If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

INSPECT CAMSHAFT OIL CLEARANCE

Clean the camshaft bearing caps, camshaft housing and camshaft journals.

Fig 48: Identifying Plastigage
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Place the camshafts on the camshaft housing.
Lay a strip of Plastigage across each of the camshaft journals.
Install the bearing caps Refer to step 30.
NOTE:
Do not turn the camshaft.
Remove the bearing caps Refer to step 41.

Measure the Plastigage at its widest point.

Fig 49: Measuring Plastigage At Camshaft Widest Point

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard oil clearance

Item	Oil Clearance
No. 1 journal	0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journal	0.025 to 0.062 mm (0.00098 to 0.0024 in.)

Maximum oil clearance

Item	Oil Clearance
No. 1 journal	0.10 mm (0.0039 in.)
Other journal	0.09 mm (0.0035 in.)

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

Clean the camshaft 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 50: Identifying Strip Of Plastigage Across Camshaft Journals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the bearing caps Refer to step 30.
NOTE:
Do not turn the camshaft.
Remove the bearing caps Refer to step 41.

Measure the Plastigage at its widest point.

Fig 51: Measuring Plastigage At Camshaft Widest Point

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard oil clearance

Item	Oil Clearance
No. 1 journal	0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journal	0.025 to 0.062 mm (0.00098 to 0.0024 in.)

Maximum oil clearance

Item	Oil Clearance
No. 1 journal	0.10 mm (0.0039 in.)
Other journal	0.09 mm (0.0035 in.)

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

INSPECT CONNECTING ROD THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
  
  Fig 52: Measuring Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard thrust clearance
  
  0.15 to 0.40 mm (0.0059 to 0.0157 in.)
  
  Maximum thrust clearance
  
  0.50 mm (0.020 in.)
  
  If the thrust clearance is greater than the maximum, replace the connecting rod assemblies. If necessary, replace the crankshaft.

INSPECT CONNECTING ROD OIL CLEARANCE

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 53: 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 54: Identifying Front Mark Of Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the connecting rod cap Refer to step 10.
NOTE:
Do not turn the crankshaft.
Remove the 2 bolts and connecting rod cap Refer to step 61.

Measure the Plastigage at its widest point.

Fig 55: Measuring Plastigage Widest Point

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard oil clearance

0.045 to 0.067 mm (0.0018 to 0.0026 in.)

Maximum oil clearance

0.070 mm (0.0028 in.)

If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect 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, 3 or 4 mark on its surface.

Connecting rod diameter

Mark	Diameter
1	56.000 to 56.006 mm (2.2047 to 2.2050 in.)
2	56.007 to 56.012 mm (2.2050 to 2.2052 in.)
3	56.013 to 56.018 mm (2.2052 to 2.2054 in.)
4	56.019 to 56.024 mm (2.2055 to 2.2057 in.)

Connecting rod bearing center wall thickness

Mark	Thickness
1	1.481 to 1.484 mm (0.0583 to 0.0584 in.)
2	1.484 to 1.487 mm (0.0584 to 0.0585 in.)
3	1.487 to 1.490 mm (0.0585 to 0.0587 in.)
4	1.490 to 1.493 mm (0.0587 to 0.0588 in.)

Crankshaft pin diameter

52.992 to 53.000 mm (2.0863 to 2.0866 in.)

NOTE:

Completely remove the Plastigage after the measurement.

INSPECT CRANKSHAFT THRUST CLEARANCE
1. Install the crankshaft bearing cap Refer to step 9.
2. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
  
  Fig 56: Measuring Crankshaft Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard thrust clearance
  
  0.04 to 0.24 mm (0.0016 to 0.0094 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
  
  2.43 to 2.48 mm (0.0957 to 0.0976 in.)
INSPECT CYLINDER BLOCK FOR WARPAGE
1. Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.
  
  Fig 57: Measuring Warpage Of Contact Surface Of Cylinder Head Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum warpage
  
  0.07 mm (0.0028 in.)
  
  If the warpage is greater than the maximum, replace the cylinder block.
2. Visually check the cylinder for vertical scratches.
  
  Fig 58: Checking Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If deep scratches are present, rebore all the 6 cylinders. If necessary, replace the cylinder block.
INSPECT CYLINDER BORE
1. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
  
  Fig 59: Measuring Cylinder Bore Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard diameter
  
  94.000 to 94.012 mm (3.7008 to 3.7013 in.)
  
  Maximum diameter
  
  94.200 mm (3.7087 in.)
  
  If the diameter is greater than the maximum, replace the cylinder block.
INSPECT PISTON SUB-ASSEMBLY WITH PIN
1. Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston end as specified.
  
  Fig 60: Measuring Clearance Between Piston Ring And Ring Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Distance
  
  8.9 mm (0.3504 in.)
  
  Standard diameter
  
  93.960 to 93.980 mm (3.6992 to 3.7000 in.)
  
  Minimum diameter
  
  93.830 mm (3.6941 in.)
INSPECT PISTON OIL CLEARANCE
1. Measure the cylinder bore diameter in the thrust direction.
2. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
  Standard oil clearance
  
  0.020 to 0.052 mm (0.0008 to 0.0020 in.)
  
  Maximum oil clearance
  
  0.060 mm (0.0024 in.)
  
  If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.

INSPECT RING GROOVE CLEARANCE

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

Fig 61: Measuring Ring Groove

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Ring groove clearance

Item	Clearance
No. 1	0.020 to 0.070 mm (0.0008 to 0.0028 in.)
No. 2	0.020 to 0.060 mm (0.0008 to 00024 in.)
Oil	0.070 to 0.150 mm (0.0028 to 0.0059 in.)

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

INSPECT PISTON RING END GAP

Insert the piston ring into the cylinder bore.

Fig 62: Inserting Piston Ring Into Cylinder Bore
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

Using a feeler gauge, measure the end gap.

Fig 63: Measuring End Gap

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard end gap

Item	End Gap
No. 1	0.25 to 0.35 mm (0.0098 to 0.0138 in.)
No. 2	0.50 to 0.60 mm (0.0197 to 0.0236 in.)
Oil	0.10 to 0.40 mm (0.0039 to 0.0157 in.)

Maximum end gap

Item	End Gap
No. 1	0.50 mm (0.0197 in.)
No. 2	0.85 mm (0.0335 in.)
Oil	0.60 mm (0.0236 in.)

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, replace the cylinder block.

INSPECT PISTON PIN OIL CLEARANCE

Using a caliper gauge, measure the inside diameter of the piston pin hole.

Fig 64: Measuring Inside Diameter Of Piston Pin Hole

Piston pin hole inside diameter

Mark	Diameter
A	22.001 to 22.004 mm (0.8662 to 0.8663 in.)
B	22.004 to 22.007 mm (0.8663 to 0.8664 in.)
C	22.007 to 22.010 mm (0.8664 to 0.8665 in.)

Using a micrometer, measure the piston pin diameter.

Fig 65: Checking Piston Pin Diameter

Piston pin diameter

Mark	Diameter
A	21.997 to 22.000 mm (0.8660 to 0.8661 in.)
B	22.000 to 22.003 mm (0.8661 to 0.8663 in.)
C	22.003 to 22.006 mm (0.8663 to 0.8664 in.)

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 0.0003 in.)

Maximum oil clearance

0.015 mm (0.0006 in.)

HINT:

If the oil clearance is greater than the maximum, replace the piston and piston pin as a set.

Using a caliper gauge, measure the inside diameter of the connecting rod bushing.

Fig 66: Checking Inside Diameter Of Connecting Rod Bushing

Bushing inside diameter

Mark	Diameter
A	22.005 to 22.008 mm (0.8663 to 0.8665 in.)
B	22.009 to 22.011 mm (0.8665 to 0.8666 in.)
C	22.012 to 22.014 mm (0.8666 to 0.8667 in.)

Subtract the piston pin diameter measurement from the bushing inside diameter measurement.

Fig 67: Identifying Front Mark Of Piston Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard oil clearance

0.005 to 0.011 mm (0.0002 to 0.0004 in.)

Maximum oil clearance

0.03 mm (0.0012 in.)

HINT:

If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin as a set.

INSPECT CONNECTING ROD
1. Using a rod aligner and feeler gauge, check the connecting rod alignment.
  
  Fig 68: Checking Connecting Rod Alignment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Check for out-of-alignment.
    Maximum out-of-alignment
    
    0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
    
    If the out-of-alignment is greater than the maximum, replace the connecting rod assembly.
  2. Check for twist.
    
    Fig 69: Checking Connecting Rod For Twist
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    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 assembly.
REMOVE CONNECTING ROD SMALL END BUSH
1. Using SST and a press, press out the bush.
  
  Fig 70: Pressing Out Bush Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09222-30010
INSPECT CONNECTING ROD BOLT
1. Using a vernier caliper, measure the tension portion diameter of the bolt.
  
  Fig 71: Identifying Tension Portion Diameter Of Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSPECT CRANKSHAFT
1. Inspect for circle runout.
  
  Fig 72: Checking Circle Runout At Center Journal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Clean the crank journal.
  2. Place the crankshaft on the V-blocks.
  3. Using a dial indicator, measure the circle runout at the center journal.
    Maximum circle runout
    
    0.06 mm (0.0024 in.)
    
    If the circle runout is greater than the maximum, replace the crankshaft.
2. Inspect the main journals.
  
  Fig 73: Checking Main Journal For Taper And Out-Of Round
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using a micrometer, measure the diameter of each main journal.
    Standard journal diameter
    
    60.988 to 61.00 mm (2.4011 to 2.4016 in.)
    
    If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.
  2. Check each main journal for taper and out-of-round as shown in the illustration.
    Maximum taper and out-of-round
    
    0.02 mm (0.0008 in.)
    
    If the taper and out-of-round is greater than the maximum, replace the crankshaft.
3. Inspect the crank pin.
  
  Fig 74: Checking Crank Pin For Taper And Out-Of Round
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Using a micrometer, measure the diameter of each crank pin.
    Diameter
    
    52.992 to 53.000 mm (2.0863 to 2.0866 in.)
    
    If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.
  2. Check each crank pin for taper and out-of-round as shown in the illustration.
    Maximum taper and out-of-round
    
    0.02 mm (0.0008 in.)
    
    If the taper and out-of-round is greater than the maximum, replace the crankshaft.

INSPECT CRANKSHAFT OIL CLEARANCE

NOTE:

Main bearings come in widths of 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

Clean the main journal and the both surfaces of the bearing.

Fig 75: Identifying Journal Bearings Diameter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the upper bearing.

Fig 76: Installing Upper Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the upper bearing to the cylinder block as shown in the illustration.
  NOTE:
  Do not apply engine oil to the bearing and its contact surface.
Install the lower bearing.

Fig 77: Identifying Lower Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the lower bearing to the bearing cap.
2. Using a vernier caliper, measure the distance between the bearing cap's edge and the lower bearing's edge.
  Dimension (A - B)
  
  0.7 mm (0.0276 in.) or less
  
  NOTE:
  Do not apply engine oil to the bearing's contact area and underside.
Place the crankshaft on the cylinder block.
Lay a strip of Plastigage across each journal.

Fig 78: Laying Strip Of Plastigage Across Journal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Examine the front marks and numbers and install the bearing caps on the cylinder block.
HINT:

A number is marked on each main bearing cap to indicate the installation position.
Apply a light coat of engine oil to the threads and under the head of bearing cap bolts.
Temporarily install the 8 main bearing cap bolts to the inside positions.
Insert the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.

Fig 79: Identifying Bolt Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bolt length

100 to 102 mm (3.94 to 4.02 in.)
Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.

Fig 80: Tapping Bearing Cap To Ensure Proper Fit
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply a light coat of engine oil to the threads and under the head of the 8 main bearing cap bolts.
Install the 8 main bearing cap bolts to the outside positions.

Fig 81: Identifying Main Bearing Cap Bolt Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bolt length

105.5 to 107.5 mm (4.15 to 4.23 in.)
Install and uniformly tighten the 16 main bearing cap bolts in several steps and in the sequence shown in the illustration.

Fig 82: Tightening Main Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf)
Mark the front side of the bearing cap bolts with paint.

Fig 83: Identifying Paint Mark On Bearing Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Tighten the bearing cap bolts another 90° in the sequence shown in the illustration.
Check that the painted mark is now at a 90° angle to the front.
NOTE:
Do not turn the crankshaft.
Install and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration.

Fig 84: Identifying Bearing Cap Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 52 N*m (525 kgf*cm, 38 ft.*lbf)

HINT:
- Bolt (A) length: 45 mm (1.77 in.)
- Except bolt (A) length: 30 mm (1.18 in.)
Remove the main bearing caps.
Measure the Plastigage at its widest point.

Fig 85: Measuring Plastigage At Widest Point
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard oil clearance

0.026 to 0.047 mm (0.0010 to 0.0019 in.)

Maximum clearance

0.050 mm (0.0020 in.)

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

NOTE:
Completely remove the Plastigage.

If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

Fig 86: Identifying Number Mark On Crankshaft Bearing

JOURNAL BEARINGS:

Cylinder block (A) + Crankshaft	0 - 5	6 - 11	12 - 17	18 - 23	24 - 28
Use Bearing	"1"	"2"	"3"	"4"	"5"

HINT:

EXAMPLE: Cylinder block "11" + Crankshaft "06" = Total number 17 (Use bearing "3")

Crankshaft main journal diameter

Mark	Diameter
"00"	60.999 to 61.000 mm (2.4015 to 2.4016 in.)
"01"	60.998 to 60.999 mm (2.4015 to 2.4015 in.)
"02"	60.997 to 60.998 mm (2.4015 to 2.4015 in.)
"03"	60.996 to 60.997 mm (2.4014 to 2.4015 in.)
"04"	60.995 to 60.996 mm (2.4014 to 2.4014 in.)
"05"	60.994 to 60.995 mm (2.4013 to 2.4014 in.)
"06"	60.993 to 60.994 mm (2.4013 to 2.4013 in.)
"07"	60.992 to 60.993 mm (2.4013 to 2.4013 in.)
"08"	60.991 to 60.992 mm (2.4012 to 2.4013 in.)
"09"	60.990 to 60.991 mm (2.4012 to 2.4012 in.)
"10"	60.989 to 60.990 mm (2.4011 to 2.4012 in.)
"11"	60.988 to 60.989 mm (2.4011 to 2.4011 in.)

Standard upper bearing center wall thickness (No. 1 and No. 4 journals)

Mark	Diameter
"1"	2.500 to 2.503 mm (0.0984 to 0.0985 in.)
"2"	2.503 to 2.506 mm (0.0985 to 0.0987 in.)
"3"	2.506 to 2.509 mm (0.0987 to 0.0988 in.)
"4"	2.509 to 2.512 mm (0.0988 to 0.0989 in.)
"5"	2.512 to 2.515 mm (0.0989 to 0.0990 in.)

Standard lower bearing center wall thickness (No. 1 and No. 4 journals)

Mark	Diameter
"1"	2.478 to 2.481 mm (0.0976 to 0.0977 in.)
"2"	2.481 to 2.484 mm (0.0977 to 0.0978 in.)
"3"	2.484 to 2.487 mm (0.0978 to 0.0979 in.)
"4"	2.487 to 2.490 mm (0.0979 to 0.0980 in.)
"5"	2.490 to 2.493 mm (0.0980 to 0.0981 in.)

Standard upper bearing center thickness (No. 2 and No. 3 journals)

Mark	Diameter
"1"	2.478 to 2.481 mm (0.0976 to 0.0977 in.)
"2"	2.481 to 2.484 mm (0.0977 to 0.0978 in.)
"3"	2.484 to 2.487 mm (0.0978 to 0.0979 in.)
"4"	2.487 to 2.490 mm (0.0979 to 0.0980 in.)
"5"	2.490 to 2.493 mm (0.0980 to 0.0981 in.)

Standard lower bearing center thickness (No. 2 and No. 3 journals)

Mark	Diameter
"1"	2.500 to 2.503 mm (0.0984 to 0.0985 in.)
"2"	2.503 to 2.506 mm (0.0985 to 0.0987 in.)
"3"	2.506 to 2.509 mm (0.0987 to 0.0988 in.)
"4"	2.509 to 2.512 mm (0.0988 to 0.0989 in.)
"5"	2.512 to 2.515 mm (0.0989 to 0.0990 in.)

INSPECT CRANKSHAFT BEARING CAP SET BOLT
1. Using a vernier caliper, measure the minimum diameter of the compressed thread at the measuring point.
  
  Fig 87: Identifying Crankshaft Bearing Cap Bolt Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard diameter
  
  10.8 to 11.0 mm (0.4252 to 0.4331 in.)
  
  Minimum diameter
  
  10.7 mm (0.4213 in.)
  
  Measuring point
  
  40 mm (1.57 in.)
  
  If the diameter is less than the minimum, replace the bolt.