Inspection [08/2013 - ]

WARNING: This page is about a different car, the 2014 Lexus ES 300h. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Turn the roller by hand to check that it turns smoothly.
  
  Fig 1: Inspecting No. 1 Valve Rocker Arm Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the roller does not turn smoothly, replace the No. 1 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.

Fig 2: Inspecting Valve Lash Adjuster Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Plunger
*2	Check Ball
*a	CORRECT
*b	INCORRECT
*c	Taper Part
*d	Low Pressure Chamber
*e	High Pressure Chamber

Place the valve lash adjuster assembly into a container full of new engine oil.
Insert the tip of SST into the valve 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 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, the high-pressure chamber will not bled.
After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers.
OK

Plunger is very difficult to move.

If the result is not as specified, replace the valve lash adjuster assembly.

INSPECT CAMSHAFT OIL CLEARANCE See step 8
INSPECT CAMSHAFT THRUST CLEARANCE See step 9

INSPECT CAMSHAFT

Inspect the camshaft runout.

Fig 3: Measuring 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
  
  0.03 mm (0.00118 in.)
  
  If the circle runout is more than the maximum, replace the camshaft.
  
  HINT:
  
  Check the oil clearance after replacing the camshaft.

Inspect the cam lobes.

Fig 4: Measuring Cam Lobe Height

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the cam lobe height.

Standard Cam Lobe Height

Item	Specified Condition
Intake	43.814 to 43.914 mm (1.725 to 1.729 in.)
Exhaust	42.939 to 43.039 mm (1.691 to 1.694 in.)

Minimum Cam Lobe Height

Item	Specified Condition
Intake	43.704 mm (1.721 in.)
Exhaust	42.829 mm (1.686 in.)

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

Inspect the camshaft journals.

Fig 5: Measuring Camshaft Journal Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 See step 8.

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

Align and insert the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

Fig 6: Identifying No. 1 Camshaft Knock Pin & Camshaft 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 assembly and camshaft flange.

Fig 7: Identifying No Clearance Between Camshaft Timing Gear Assembly And Camshaft Flange

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Camshaft Timing Gear Assembly
*2	Camshaft Flange
*a	INCORRECT
*b	CORRECT
*c	Clearance
*d	No Clearance

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

Release the lock pin.

Fig 8: Identifying Lock Pin

TEXT IN ILLUSTRATION

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

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.
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 approximately 200 kPa (2.0 kgf/ cm² , 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

Fig 9: View Of Using Air Pressure To Turn 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 spraying.

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

HINT:
- Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.
- 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 assembly within its movable range (19.0 to 21.0°) 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 rubber pieces from the camshaft.
Remove the bolt and camshaft timing gear assembly.

INSPECT CHAIN SUB-ASSEMBLY
1. Using a spring scale, pull the chain sub-assembly with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.
  
  Fig 10: Measuring Chain Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Measurement Area
2. Using a vernier caliper, measure the length of 15 pins.
  Maximum chain elongation
  
  137.7 mm (5.42 in.)
  
  HINT:
  
  Perform the measurement at 3 random places.
  
  If the elongation is more than the maximum, replace the chain sub-assembly.
INSPECT CAMSHAFT TIMING SPROCKET
1. Place the chain sub-assembly around the camshaft timing sprocket.
  
  Fig 11: Measuring Sprocket Diameter With Chain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a vernier caliper, measure the camshaft timing sprocket diameter with the chain sub-assembly.
  Minimum sprocket diameter (with chain)
  
  115.12 mm (4.53 in.)
  
  If the diameter is less than the minimum, replace the chain sub-assembly and camshaft timing sprocket.
  
  HINT:
  
  The vernier caliper must contact the chain sub-assembly rollers for the measurement.
INSPECT CRANKSHAFT TIMING SPROCKET
1. Place the chain sub-assembly around the crankshaft timing sprocket.
  
  Fig 12: Measuring Sprocket Diameter With Chain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a vernier caliper, measure the crankshaft timing sprocket diameter with the chain sub-assembly.
  Minimum sprocket diameter (with chain)
  
  59.94 mm (2.36 in.)
  
  If the diameter is less than the minimum, replace the chain sub-assembly and crankshaft timing sprocket.
  
  HINT:
  
  The vernier caliper must contact the chain sub-assembly rollers for the measurement.

INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

Move the stopper plate counterclockwise to release the lock. Push the plunger and check that it moves smoothly.

Fig 13: Identifying Plunger & Stopper Plate

TEXT IN ILLUSTRATION

*1	Plunger
*2	Stopper Plate

If the plunger does not move smoothly, replace the No. 1 chain tensioner assembly.

INSPECT CHAIN TENSIONER SLIPPER
1. Measure the wear depth of the chain tensioner slipper.
  
  Fig 14: Measuring Wear Depth Of Chain Tensioner Slipper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Depth
  
  Maximum depth
  
  1.0 mm (0.0394 in.)
  
  If the depth is more than the maximum, replace the chain tensioner slipper.
INSPECT NO. 1 CHAIN VIBRATION DAMPER
1. Measure the wear depth of the No. 1 chain vibration damper.
  
  Fig 15: Measuring Wear Depth Of No. 1 Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Depth
  
  Maximum depth
  
  1.0 mm (0.0394 in.)
  
  If the depth is more than the maximum, replace the No. 1 chain vibration damper.
INSPECT TIMING CHAIN GUIDE
1. Measure the wear depth of the timing chain guide.
  
  Fig 16: Measuring Wear Depth Of Timing Chain Guide
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Depth
  
  Maximum depth
  
  1.0 mm (0.0394 in.)
  
  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 17: Measuring 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 18: Measuring 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. Secure 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 19: Measuring No. 1 And No. 2 Balance Shafts Backlash
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Fix
  
  Standard backlash
  
  0.04 to 0.17 mm (0.00157 to 0.00669 in.)
  
  Maximum backlash
  
  0.17 mm (0.00669 in.)
  
  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 threads at the measurement point.
  
  Fig 20: Inspecting Cylinder Head Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Measurement Point
  
  Standard diameter
  
  10.85 to 11.00 mm (0.427 to 0.433 in.)
  
  Minimum diameter
  
  10.6 mm (0.417 in.)
  
  Measurement point (distance from the seat)
  
  106 mm (4.17 in.)
  
  HINT:
  - If the diameter is less than the minimum, replace the cylinder head bolt with a new one. Failure to do so may lead to engine damage.
  - If there is any thread deformation, replace the cylinder head bolt with a new one.
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 21: Checking Exhaust Manifold Surface Warpage
  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 converter sub-assembly.