Inspection [06/2016 - ]: Procedure

1. Check that the roller moves smoothly by rotating it by hand.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Replace the No. 1 valve rocker arm sub-assembly if the roller does not rotate smoothly.

1. Check the chain sub-assembly for deformation, cracks or other damages.

   If the chain sub-assembly has any defects, replace it.

1. Check the camshaft timing gear teeth for abnormal wear and scratches.

   If the camshaft timing gear has any defects, replace it.

1. Check the crankshaft timing gear or sprocket teeth for abnormal wear and scratches.

   If necessary, replace it.

2. Check that there is no play between the crankshaft timing gear or sprocket and the key.

   If necessary, replace the crankshaft timing gear or sprocket or the key.

1. Check the chain tensioner slipper for deformation, cracks or other damages.

1. Check the No. 1 chain vibration damper for deformation, cracks or other damages.

1. Check the chain tensioner assembly for deformation, cracks or other damages.
2. Check that the plunger moves smoothly when it is unlocked.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If the plunger does not move smoothly, replace the chain tensioner assembly.

3. Check that the plunger does not move when it is locked.

1. Visually check the oil control valve filters, and if clogging is found, replace them with new ones.
2. Check the camshaft housing sub-assembly journals for damage and wear. Replace the camshaft housing sub-assembly if necessary.

1. Check the camshaft journals for damage and wear.

   Replace the camshaft if necessary.

2. Check the cam face condition.

   Replace the camshaft if uneven wear is found.

   HINT: 

   Remove the minor faults by smoothing the surface with 400-grit sandpaper.

3. Inspect for runout.
   1. Place the camshaft on V-blocks.
   2. Using a dial indicator, measure the circle runout at the center journal.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum circle runout

      0.020 mm (0.00079 in.)

      If the circle runout is more than the maximum, replace the camshaft.

      HINT: 

      Measurement should be performed at a temperature of 20°C (68°F).

4. Inspect for cam height.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using a micrometer, measure the cam lobe height.

      Standard height (Intake)

      Position	Standard
      A	40.39 to 40.49 mm (1.5902 to 1.5941 in.)
      B	34.0 mm (1.3386 in.)

      Standard height (Exhaust)

      Position	Standard
      A	40.19 to 40.29 mm (1.5823 to 1.5862 in.)
      B	34.0 mm (1.3386 in.)

      Standard height (For fuel pump)

      Position	Standard
      C	38.95 to 39.05 mm (1.5335 to 1.5374 in)

      TEXT IN ILLUSTRATION
      
      

      *a	For Valve
      *b	For Fuel Pump

      If the result is not as specified, replace the camshaft.

      HINT: 

      Measurement should be performed at a temperature of 20°C (68°F).

5. Inspect for camshaft journals.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using a micrometer, measure the journal diameter.

      Standard journal diameter

      25.946 to 25.963 mm (1.02149 to 1.02216 in.)

      If the result is not as specified, check the oil clearance.

      HINT: 

      Measurement should be performed at a temperature of 20°C (68°F).

1. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard thrust clearance

   0.0068 to 0.1160 mm (0.00027 to 0.00457 in.)

   If the clearance is not as specified or if uneven wear is found, replace each camshaft cap and camshaft housing as a set. If necessary replace the camshaft.

   HINT: 

   • Measurement should be performed at a temperature of 20°C (68°F).
   • Set the dial indicator at the end surface of the camshaft.

HINT: 

Measurement should be performed at a temperature of 20°C (68°F).

1. Remove the seal packing from camshaft housing and front camshaft cap, intake rear camshaft cap and exhaust rear camshaft cap.
2. Clean each camshaft cap and camshaft housing journal.
3. Set the camshafts on the camshaft housing.
4. Place a plastigauge across the camshaft journals and set the camshaft caps.
5. Tighten the bolts in the order shown in the illustration to install the front camshaft cap, intake center camshaft cap, intake rear camshaft cap, exhaust center camshaft cap and exhaust rear camshaft cap.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *a

   for Bank 1

   *b

   for Bank 2

   Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

6. Using several steps, uniformly loosen the bolts in the order shown in the illustration, and remove the front camshaft cap, intake center camshaft cap, intake rear camshaft cap, exhaust center camshaft cap and exhaust rear camshaft cap.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *a

   for Bank 1

   *b

   for Bank 2

7. Measure the widest point of the plastigauge on each journal.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard oil clearance

   0.037 to 0.072 mm (0.00146 to 0.00283 in.)

   If the clearance is not as specified, replace each camshaft cap and camshaft housing as a set. If necessary, replace the camshaft.

8. Completely remove the plastigauge.