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Inspection [04/2013 - 08/2015]: Procedure

WARNING: This page is about a different car, the 2015 Lexus IS 250 and 2014 Lexus IS 250. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Turn the roller by hand to check that it turns smoothly.

      If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.

      GTY121531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT VALVE LASH ADJUSTER ASSEMBLY 
    NOTE:
    • Keep the valve lash adjuster assembly free of dirt and foreign objects.
    • Only use clean engine oil.
    1. Place the valve lash adjuster assembly into a container filled with engine oil.
    2. Insert the tip of SST into the valve lash adjuster assembly plunger and use the tip to press down on the check ball inside the plunger.
      • SST: 09276-75010 
      GTY467825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Tapered Path *2 Plunger
      *3 Low Pressure Chamber *4 Check Ball
      *5 High Pressure Chamber - -
      *a CORRECT *b INCORRECT
    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 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 air, remove SST. Then try to quickly and firmly press the plunger with your fingers.

      OK

      Plunger is very difficult to move.

      If the plunger can still be compressed after bleeding air 3 times, replace the valve lash adjuster with a new one.

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

        Maximum circle runout

        0.08 mm (0.00315 in.)

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

        HINT: 

        Check the oil clearance after replacing the camshaft.

        See step  18

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

      Standard Cam Lobe Height

      Item Specified Condition
      Intake 43.940 to 44.040 mm (1.7299 to 1.7339 in.)
      Exhaust 44.090 to 44.190 mm (1.7358 to 1.7398 in.)
      Exhaust (for Fuel Pump) 56.450 to 56.550 mm (2.2224 to 2.2264 in.)

      Minimum Cam Lobe Height

      Item Specified Condition
      Intake 43.790 mm (1.7240 in.)
      Exhaust 43.940 mm (1.7299 in.)
      Exhaust (for Fuel Pump) 56.300 mm (2.2165 in.)
    3. Using a micrometer, measure the journal diameter.

      Standard Journal Diameter

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

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

      See step  18

  4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Install the camshaft timing gear assembly.

      Refer to PROCEDURE - Step 1

    2. Inspect the camshaft timing gear assembly.

      Refer to PROCEDURE - Step 26

    3. Remove the flange bolt and camshaft timing gear assembly.
      GTY456546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Do Not Remove
      NOTE:
      • Do not remove the other 3 bolts.
      • If planning to reuse the camshaft timing gear assembly, be sure to release the straight pin lock before installing the camshaft timing gear assembly.
  5. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Install the camshaft timing exhaust gear assembly.

      Refer to PROCEDURE - Step 2

    2. Inspect the camshaft timing exhaust gear assembly.

      Refer to PROCEDURE - Step 28

    3. Remove the flange bolt and camshaft timing exhaust gear assembly.
      GTY461878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Do Not Remove
      NOTE:
      • Be sure not to remove the other 4 bolts.
      • If planning to reuse the camshaft timing exhaust gear assembly, be sure to release the straight pin lock before installing the camshaft timing exhaust gear assembly.
  6. INSPECT CYLINDER HEAD SET BOLT 
    1. Using a vernier caliper, measure the length of the cylinder head set bolt from the seat to the end.
      GTY463878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Measurement Length

      Standard length

      141.3 to 142.7 mm (5.56 to 5.62 in.)

      Maximum length

      143.7 mm (5.66 in.)

      If the length is more than the maximum, replace the cylinder head set bolt.

    2. Using a vernier caliper, measure the diameter of the elongated thread at the narrowest visible area.
      GTY465377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Measurement Point
      *a Approximately 100 mm (3.94 in.)

      Standard diameter

      10.80 to 11.00 mm (0.425 to 0.433 in.)

      Minimum diameter

      10.70 mm (0.421 in.)

      NOTE:
      • If the diameter is less than the minimum, replace the cylinder head set bolt. Failure to do so may lead to engine damage.
      • If there is any thread deformation, replace the cylinder head set bolt with a new one.
  7. INSPECT CHAIN SUB-ASSEMBLY 
    1. Using a spring scale, pull the chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) and measure the length of the chain sub-assembly using a vernier caliper.
      GTY462135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Measurement Area

      Maximum chain elongation

      136.9 mm (5.39 in.)

      HINT: 

      Perform the measurement at 3 random places. If a measurement is more than the maximum, replace the chain sub-assembly.

  8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY 
    GTY469832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *1 Measurement Area
    1. Using a spring scale, pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) and measure the length of the No. 2 chain sub-assembly using a vernier caliper.

      Maximum chain elongation

      137.6 mm (5.42 in.)

      HINT: 

      Perform the measurement at 3 random places. If a measurement is more than the maximum, replace the No. 2 chain sub-assembly.

  9. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET 
    1. Place the chain sub-assembly around the crankshaft timeng gear or sprocket.
    2. Using a vernier caliper, measure the crankshaft timing gear or sprocket diameter with the chain sub-assembly.
      GTY145630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Minimum sprocket diameter (with chain sub-assembly)

      61.4 mm (2.42 in.)

      HINT: 

      The vernier caliper must contact the chain rollers for the measurement.

      If the diameter is less than the minimum, replace the chain sub-assembly and crankshaft timeng gear or sprocket.

  10. INSPECT IDLE SPROCKET ASSEMBLY 
    1. Place the chain sub-assembly around the idle sprocket assembly.
    2. Using a vernier caliper, measure the idle sprocket assembly diameter with the chain sub-assembly.
      GTY136269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Minimum sprocket diameter (with chain sub-assembly)

      61.4 mm (2.42 in.)

      HINT: 

      The vernier caliper must contact the chain rollers for the measurement.

      If the diameter is less than the minimum, replace the chain sub-assembly and idle sprocket assembly.

  11. INSPECT IDLE GEAR SHAFT OIL CLEARANCE 
    1. Using a micrometer, measure the No. 1 idle gear shaft diameter.

      Standard diameter

      22.987 to 23.000 mm (0.905 to 0.906 in.)

      GTY104400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a caliper gauge, measure the inside diameter of the idle sprocket assembly.

      Standard diameter

      23.020 to 23.030 mm (0.906 to 0.907 in.)

      GTY104840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Subtract the No. 1 idle gear shaft diameter measurement from the idle sprocket assembly inside diameter measurement.

      Standard oil clearance

      0.020 to 0.043 mm (0.00079 to 0.00169 in.)

      Maximum oil clearance

      0.093 mm (0.00366 in.)

      If the thrust oil clearance is more than the maximum, replace the No. 1 idle gear shaft and idle sprocket assembly.

  12. 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.

      GTY461391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Plunger
      *2 Stopper Plate
  13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY 
    GTY470813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Depth
    *b Moves Smoothly
    1. Check that the plunger moves smoothly.
    2. Measure the depth of wear of the No. 2 chain tensioner assembly.

      Maximum depth

      0.9 mm (0.0354 in.)

      If the depth is more than the maximum, replace the No. 2 chain tensioner assembly.

  14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY 
    GTY456702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Depth
    *b Moves Smoothly
    1. Check that the plunger moves smoothly.
    2. Measure the depth of wear of the No. 3 chain tensioner assembly.

      Maximum depth

      0.9 mm (0.0354 in.)

      If the depth is more than the maximum, replace the No. 3 chain tensioner assembly.

  15. INSPECT CHAIN TENSIONER SLIPPER 
    1. Measure the depth of wear of the chain tensioner slipper.
      GTY463065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth

      Maximum depth

      1.0 mm (0.0394 in.)

      If the depth is more than the maximum, replace the chain tensioner slipper.

  16. INSPECT NO. 1 CHAIN VIBRATION DAMPER 
    1. Measure the depth of wear of the No. 1 chain vibration damper.
      GTY466216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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.

  17. INSPECT NO. 2 CHAIN VIBRATION DAMPER 
    1. Measure the depth of wear of the No. 2 chain vibration damper.
      GTY462849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth

      Maximum depth

      1.0 mm (0.0394 in.)

      If the depth is more than the maximum, replace the No. 2 chain vibration damper.

  18. INSPECT CAMSHAFT OIL CLEARANCE 
    1. for Bank 1:
      1. Clean the camshaft bearing caps, camshaft housing sub-assembly RH and camshaft journals.
      2. Place the camshafts on the camshaft housing sub-assembly RH.
      3. Lay a strip of Plastigage across each camshaft journal.
        GTY459121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Plastigage
      4. Install the camshaft bearing caps.
        NOTE:

        Do not turn the camshafts.

        Refer to PROCEDURE - Step 22

      5. Remove the camshaft bearing caps.

        Refer to PROCEDURE - Step 8

      6. Measure the Plastigage at its widest point.
        GTY471207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Plastigage
        *2 No. 1 Journal
        *3 Other Journals
        *a Intake Side
        *b Exhaust Side

        Standard Oil Clearance

        Item Specified Condition
        Exhaust side No. 1 journal 0.031 to 0.078 mm (0.00122 to 0.00307 in.)
        Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.)

        Maximum Oil Clearance

        Item Specified Condition
        Exhaust side No. 1 journal 0.10 mm (0.00394 in.)
        Other journals 0.09 mm (0.00354 in.)

        If the oil clearance is more than the maximum, replace the camshaft.

        If the oil clearance is still more than the maximum after replacing the camshaft, replace the camshaft housing sub-assembly RH.

    2. for Bank 2:
      1. Clean the camshaft bearing caps, camshaft housing sub-assembly LH and camshaft journals.
      2. Place the camshafts on the camshaft housing sub-assembly LH.
      3. Lay a strip of Plastigage across each camshaft journal.
        GTY470572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Plastigage
      4. Install the camshaft bearing caps.
        NOTE:

        Do not turn the camshafts.

        Refer to PROCEDURE - Step 18

      5. Remove the camshaft bearing caps.

        Refer to PROCEDURE - Step 14

      6. Measure the Plastigage at its widest point.
        GTY469556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Plastigage
        *2 No. 1 Journal
        *3 Other Journals
        *a Intake Side
        *b Exhaust Side

        Standard Oil Clearance

        Item Specified Condition
        Exhaust side No. 1 journal 0.031 to 0.078 mm (0.00122 to 0.00307 in.)
        Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.)

        Maximum Oil Clearance

        Item Specified Condition
        Exhaust side No. 1 journal 0.10 mm (0.00394 in.)
        Other journals 0.09 mm (0.00354 in.)

        If the oil clearance is more than the maximum, replace the camshaft.

        If the oil clearance is still more than the maximum after replacing the camshafts, replace the camshaft housing sub-assembly LH.

  19. INSPECT EXHAUST MANIFOLD 
    1. Using a precision straightedge and feeler gauge, measure the warpage of the surface which contacts the cylinder head.
      GTY398631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum warpage

      0.70 mm (0.02756 in.)

      If the warpage is more than the maximum, replace the exhaust manifold sub-assembly.

  20. INSPECT INTAKE MANIFOLD 
    1. Using a precision straightedge and feeler gauge, measure the warpage of the surfaces which contact the cylinder head and intake air surge tank.
      GTY470192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Intake Air Surge Tank Side
      *b Cylinder Head Side

      Maximum warpage

      0.10 mm (0.00394 in.)

      If the warpage is more than the maximum, replace the intake manifold.

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