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Inspection [08/2013 - ]

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  1. INSPECT CYLINDER HEAD SUB-ASSEMBLY 
    1. Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head sub-assembly contacts the cylinder block sub-assembly and manifold.
      Fig 1: Measuring Warpage Of Contact Surfaces
      GTY322763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum Warpage

      Item Specified Condition
      Cylinder head lower side 0.05 mm (0.00197 in.)
      Intake manifold side 0.10 mm (0.00394 in.)
      Exhaust manifold side 0.10 mm (0.00394 in.)
      TEXT IN ILLUSTRATION

      *a Cylinder Head Lower Side
      *b Intake Manifold Side
      *c Exhaust Manifold Side

      If the warpage is more than the maximum, replace the cylinder head sub-assembly.

    2. Using a dye penetrant, check the intake ports, exhaust ports and cylinder head sub-assembly surface for cracks.
      Fig 2: Inspecting Exhaust Ports & Cylinder Surface For Cracks
      GTY188174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If cracked, replace the cylinder head sub-assembly.

  2. INSPECT COMPRESSION SPRING 
    1. Using a vernier caliper, measure the free length of the compression spring.
      Fig 3: Measuring Free Length Of Inner Compression Spring
      GTY194941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      Wire Diameter Specified Condition
      3.3 mm (0.130 in.) 49.0 to 51.0 mm (1.93 to 2.01 in.)
      3.4 mm (0.134 in.) 47.2 to 49.2 mm (1.86 to 1.94 in.)

      If the free length is not as specified, replace the compression spring.

    2. Using a steel square, measure the deviation of the compression spring.
      Fig 4: Measuring Inner Compression Spring Deviation
      GTY323016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum deviation

      1.0 mm (0.0394 in.)

      Maximum angle

      2°

      TEXT IN ILLUSTRATION

      *a Deviation

      If the deviation is more than the maximum, replace the compression spring.

  3. INSPECT INTAKE VALVE 
    1. Using a micrometer, measure the diameter of the valve stem.
      Fig 5: Measuring Diameter Of Valve Stem
      GTY188146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard valve stem diameter

      5.470 to 5.485 mm (0.21535 to 0.21594 in.)

    2. Using a vernier caliper, measure the valve head margin thickness.
      Fig 6: Measuring Valve Head Margin Thickness
      GTY320702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard margin thickness

      1.0 mm (0.0394 in.)

      Minimum margin thickness

      0.50 mm (0.0197 in.)

      TEXT IN ILLUSTRATION

      *a Margin Thickness

      If the margin thickness is less than the minimum, replace the intake valve.

    3. Using a vernier caliper, measure the overall length of the intake valve.
      Fig 7: Identifying Overall Length Of Valve
      GTY322694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard overall length

      103.92 mm (4.09 in.)

      Minimum overall length

      103.42 mm (4.07 in.)

      TEXT IN ILLUSTRATION

      *a Overall Length

      If the overall length is less than the minimum, replace the intake valve.

  4. INSPECT EXHAUST VALVE 
    1. Using a micrometer, measure the diameter of the valve stem.
      Fig 8: View Of Measuring Diameter Of Valve Stem
      GTY174373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard valve stem diameter

      5.465 to 5.480 mm (0.21516 to 0.21575 in.)

    2. Using a vernier caliper, measure the valve head margin thickness.
      Fig 9: Measuring Valve Head Margin Thickness
      GTY322320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard margin thickness

      1.0 mm (0.0394 in.)

      Minimum margin thickness

      0.50 mm (0.0197 in.)

      TEXT IN ILLUSTRATION

      *a Margin Thickness

      If the margin thickness is less than the minimum, replace the exhaust valve.

    3. Using a vernier caliper, measure the overall length of the exhaust valve.
      Fig 10: Identifying Overall Length Of Valve
      GTY316315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard overall length

      112.91 mm (4.45 in.)

      Minimum overall length

      112.41 mm (4.43 in.)

      TEXT IN ILLUSTRATION

      *a Overall Length

      If the overall length is less than the minimum, replace the exhaust valve.

  5. INSPECT VALVE GUIDE BUSH OIL CLEARANCE 
    1. Using a caliper gauge, measure the inside diameter of the valve guide bush.
      Fig 11: Measuring Inside Diameter Of Guide Bushing
      GTY188172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Valve Guide bush inside diameter

      5.510 to 5.530 mm (0.2169 to 0.2177 in.)

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

      Standard Oil Clearance

      Item Specified Condition
      Intake 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
      Exhaust 0.030 to 0.065 mm (0.00118 to 0.00256 in.)

      Maximum Oil Clearance

      Item Specified Condition
      Intake 0.08 mm (0.00315 in.)
      Exhaust 0.10 mm (0.00394 in.)

      If the oil clearance is more than the maximum, replace the valve and valve guide bush.

  6. INSPECT INTAKE VALVE SEAT 
    1. Apply a light coat of Prussian blue to the valve face.
    2. Lightly press the valve face against the intake valve seat.
      Fig 12: Inspecting Intake Valve Seat
      GTY319922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Width

      HINT: 

      Do not rotate the intake valve while pressing the it.

    3. Check the valve face and seat according to the following procedure.
      1. If Prussian blue appears 360° around the entire valve face, the valve face is concentric. If not, replace the intake valve.
      2. If Prussian blue appears 360° around the entire valve seat, the guide and face are concentric. If not, resurface the intake valve seat.
      3. Check that the seat contacts the middle of the valve face with the width between 1.1 and 1.5 mm (0.0433 and 0.0591 in.).
  7. INSPECT EXHAUST VALVE SEAT 
    1. Apply a light coat of Prussian blue to the valve face.
    2. Lightly press the valve face against the exhaust valve seat.
      Fig 13: Inspecting Exhaust Valve Seat
      GTY320718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Width

      HINT: 

      Do not rotate the exhaust valve while pressing it.

    3. Check the valve face and seat according to the following procedure.
      1. If Prussian blue appears 360° around the entire valve face, the valve face is concentric. If not, replace the exhaust valve.
      2. If Prussian blue appears 360° around the entire valve seat, the guide and face are concentric. If not, resurface the exhaust valve seat.
      3. Check that the seat contacts the middle of the valve face with the width between 1.1 and 1.5 mm (0.0433 and 0.0591 in.).
  8. INSPECT CAMSHAFT OIL CLEARANCE 
    NOTE:

    Do not turn the camshafts.

    1. Clean the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 3 No. 3 camshaft bearing caps, camshaft housing sub-assembly and camshaft journals.
    2. Place the camshaft and No. 2 camshaft on the camshaft housing sub-assembly.
    3. Lay a strip of Plastigage across each of the camshaft journals.
      Fig 14: Identifying Plastigage
      GTY322243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Plastigage
    4. Install the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps See step  13.
    5. Install the camshaft housing sub-assembly See step  14.
    6. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps See step  21.
    7. Measure the Plastigage at its widest point.
      Fig 15: Measuring Plastigage At Widest Point
      GTY320158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Oil Clearance

      Item Specified Condition
      Intake No. 1 journal 0.035 to 0.072 mm (0.00138 to 0.00283 in.)
      Exhaust No. 1 journal 0.005 to 0.054 mm (0.000197 to 0.00213 in.)
      Other journal 0.025 to 0.062 mm (0.000984 to 0.00244 in.)

      Maximum Oil Clearance

      Item Specified Condition
      Intake No. 1 journal 0.085 mm (0.00335 in.)
      Exhaust No. 1 journal 0.085 mm (0.00335 in.)
      Other journal 0.085 mm (0.00335 in.)
      TEXT IN ILLUSTRATION

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

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

  9. INSPECT CAMSHAFT THRUST CLEARANCE 
    1. Clean the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 3 No. 3 camshaft bearing caps, camshaft housing sub-assembly and camshaft journals.
    2. Place the camshaft and No. 2 camshaft on the camshaft housing sub-assembly.
    3. Install the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps See step  13.
    4. Install the camshaft housing sub-assembly See step  14.
    5. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
      Fig 16: Measuring Thrust Clearance
      GTY314958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Thrust Clearance

      Item Specified Condition
      Intake 0.060 to 0.155 mm (0.00236 to 0.00610 in.)
      Exhaust 0.060 to 0.155 mm (0.00236 to 0.00610 in.)

      Maximum Thrust Clearance

      Item Specified Condition
      Intake 0.170 mm (0.00669 in.)
      Exhaust 0.170 mm (0.00669 in.)

      If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly. If the thrust surface is damaged, replace the camshaft.

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