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Inspection [10/2018 - ]: Procedure

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  1. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Turn the roller by hand to check that it turns smoothly.
      GTY772103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

  2. INSPECT VALVE LASH ADJUSTER ASSEMBLY 
    NOTE:
    • Keep the valve lash adjuster assembly free from dirt and foreign matter.
    • 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.
      GTY774574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Correct *b Incorrect
      *c Tapered Path *d Low Pressure Chamber
      *e High Pressure Chamber *f Plunger
      *g Check Ball - -
      • 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 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 by hand.

      OK

      The plunger is very difficult to move.

      HINT: 

      If the plunger is easy to move, replace the valve lash adjuster assembly.

  3. INSPECT INTAKE CAMSHAFT SUB-ASSEMBLY 
    1. Inspect the intake camshaft sub-assembly for runout.
      GTY756740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Place the intake camshaft sub-assembly on V-blocks.
      2. Using a dial indicator, measure the runout at the center journal.

        Maximum Runout

        0.03 mm (0.00118 in.)

        HINT: 

        • If the runout is more than the maximum, replace the intake camshaft sub-assembly.
        • Check the intake camshaft sub-assembly oil clearance after replacing the intake camshaft sub-assembly.
    2. Inspect the cam lobes.
      GTY756741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a micrometer, measure the cam lobe height.

        Standard Cam Lobe Height

        42.267 to 42.367 mm (1.66405 to 1.66799 in.)

        Minimum Cam Lobe Height

        42.157 mm (1.65972 in.)

        HINT: 

        If the cam lobe height is less than the minimum, replace the intake camshaft sub-assembly.

    3. Inspect the intake camshaft sub-assembly journals.
      GTY756742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter

        Item Specified Condition
        No. 1 journal 33.984 to 34.000 mm (1.33795 to 1.33858 in.)
        Other journals 23.959 to 23.975 mm (0.94326 to 0.94389 in.)

        HINT: 

        If the journal diameter is not as specified, check the intake camshaft sub-assembly oil clearance.

        See step  5

  4. INSPECT EXHAUST CAMSHAFT SUB-ASSEMBLY 
    1. Inspect the exhaust camshaft sub-assembly for runout.
      GTY756743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Place the exhaust camshaft sub-assembly on V-blocks.
      2. Using a dial indicator, measure the runout at the center journal.

        Maximum Runout

        0.03 mm (0.00118 in.)

        HINT: 

        • If the runout is more than the maximum, replace the exhaust camshaft sub-assembly.
        • Check the camshaft oil clearance after replacing the exhaust camshaft sub-assembly.
    2. Inspect the cam lobes.
      GTY772126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a micrometer, measure the cam lobe height.

        Standard Cam Lobe Height

        Item Specified Condition
        Exhaust camshaft sub-assembly 42.162 to 42.262 mm (1.65992 to 1.66385 in.)
        Exhaust camshaft sub-assembly (for Fuel Pump) 42.946 to 43.046 mm (1.69078 to 1.69472 in.)

        Minimum Cam Lobe Height

        Item Specified Condition
        Exhaust camshaft sub-assembly 42.052 mm (1.65559 in.)
        Exhaust camshaft sub-assembly (for Fuel Pump) 42.846 mm (1.68685 in.)

        HINT: 

        If the cam lobe height is less than the minimum, replace the exhaust camshaft sub-assembly.

    3. Inspect the exhaust camshaft sub-assembly journals.
      GTY756854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter

        Item Specified Condition
        No. 1 journal 40.984 to 41.000 mm (1.61354 to 1.61417 in.)
        Other journals 23.959 to 23.975 mm (0.94326 to 0.94389 in.)

        HINT: 

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

        See step  5

  5. INSPECT CAMSHAFT OIL CLEARANCE 
    1. Clean the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 2 No. 3 camshaft bearing caps, camshaft housing sub-assembly and camshaft journals.
    2. Place the intake camshaft sub-assembly and exhaust camshaft sub-assembly on the camshaft housing sub-assembly.
    3. Lay a strip of Plastigage across each of the camshaft journals.
      GTY749030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
    4. Install the camshaft bearing caps.

      See step  25

      NOTE:

      Do not turn the camshafts.

    5. Remove the camshaft bearing caps.

      See step  36

    6. Measure the Plastigage at its widest point.

      Standard Oil Clearance (for intake camshaft sub-assembly)

      Item Specified Condition
      No. 1 journal 0.035 to 0.072 mm (0.00138 to 0.00283 in.)
      Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.)

      Standard Oil Clearance (for exhaust camshaft sub-assembly)

      Item Specified Condition
      No. 1 journal 0.027 to 0.064 mm (0.00106 to 0.00252 in.)
      Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.)

      Maximum Oil Clearance (for intake camshaft sub-assembly)

      Item Specified Condition
      No. 1 journal 0.085 mm (0.00335 in.)
      Other journals 0.085 mm (0.00335 in.)

      Maximum Oil Clearance (for exhaust camshaft sub-assembly)

      Item Specified Condition
      No. 1 journal 0.085 mm (0.00335 in.)
      Other journals 0.085 mm (0.00335 in.)
      GTY747269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
      *b No. 1 Journal
      *c Other Journal
      NOTE:

      Completely remove the Plastigage after the inspection.

      HINT: 

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

  6. 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.
      GTY751037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Measurement Length
    2. Using a vernier caliper, measure the length of 15 links.

      Maximum Chain Elongation

      116.30 mm (4.58 in.)

      NOTE:

      Perform the measurement at 3 random places. Use the average of the measurements.

      HINT: 

      If the average elongation is more than the maximum, replace the chain sub-assembly.

  7. INSPECT OIL PUMP DRIVE CHAIN SUB-ASSEMBLY 
    1. GTY739132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Measurement Length

      Using a spring scale, pull the oil pump drive chain sub-assembly with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.

    2. Using a vernier caliper, measure the length of 15 links.

      Maximum Chain Elongation

      116.30 mm (4.58 in.)

      NOTE:

      Perform the measurement at 3 random places. Use the average of the measurements.

      HINT: 

      If the average elongation is more than the maximum, replace the oil pump drive chain sub-assembly.

  8. INSPECT OIL PUMP DRIVE SPROCKET 
    1. Place the oil pump drive chain sub-assembly around the oil pump drive sprocket.
      GTY756860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a vernier caliper, measure the diameter of the oil pump drive sprocket and oil pump drive chain sub-assembly.

      Minimum Gear Diameter (with Oil Pump Drive Chain Sub-assembly)

      51.35 mm (2.02 in.)

      NOTE:

      The vernier caliper must be in contact with the chain rollers when measuring.

      HINT: 

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

  9. INSPECT OIL PUMP DRIVE SHAFT SPROCKET 
    1. Place the oil pump drive chain sub-assembly around the oil pump drive shaft sprocket.
      GTY760306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a vernier caliper, measure the diameter of the oil pump drive shaft sprocket and oil pump drive chain sub-assembly.

      Minimum Gear Diameter (with Oil Pump Drive Chain Sub-assembly)

      51.35 mm (2.02 in.)

      NOTE:

      The vernier caliper must be in contact with the chain rollers when measuring.

      HINT: 

      If the diameter is less than the minimum, replace the oil pump drive chain sub-assembly and oil pump drive shaft sprocket.

  10. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Place the chain sub-assembly around the camshaft timing gear assembly.
    2. Using a vernier caliper, measure the diameter of the camshaft timing gear assembly and chain sub-assembly.

      Minimum Gear Diameter (with Chain Sub-assembly)

      100.01 mm (3.94 in.)

      NOTE:

      The vernier caliper must be in contact with the chain rollers when measuring.

      HINT: 

      If the diameter is less than the minimum, replace the chain sub-assembly and camshaft timing gear assembly.

      GTY760305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Place the chain sub-assembly around the camshaft timing exhaust gear assembly.
    2. Using a vernier caliper, measure the diameter of the camshaft timing exhaust gear assembly and chain sub-assembly.

      Minimum Gear Diameter (with Chain Sub-assembly)

      100.01 mm (3.94 in.)

      NOTE:

      The vernier caliper must be in contact with the chain rollers when measuring.

      HINT: 

      If the diameter is less than the minimum, replace the chain sub-assembly and camshaft timing exhaust gear assembly.

      GTY772885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSPECT CRANKSHAFT TIMING SPROCKET 
    1. Place the chain sub-assembly around the crankshaft timing sprocket.
      GTY772884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a vernier caliper, measure the diameter of the crankshaft timing sprocket and chain sub-assembly.

      Minimum Sprocket Diameter (with Chain Sub-assembly)

      51.35 mm (2.02 in.)

      NOTE:

      The vernier caliper must be in contact with the chain rollers when measuring.

      HINT: 

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

  13. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Push the plunger and check that it moves smoothly.
      GTY759626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plunger

      HINT: 

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

  14. INSPECT CHAIN TENSIONER SLIPPER 
    1. Using a vernier caliper, measure the wear depth of the chain tensioner slipper.
      GTY772509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth

      Maximum Depth

      1.0 mm (0.0394 in.)

      HINT: 

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

  15. INSPECT NO. 1 CHAIN VIBRATION DAMPER 
    1. Using a vernier caliper, measure the wear depth of the No. 1 chain vibration damper.
      GTY764339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth

      Maximum Depth

      1.0 mm (0.0394 in.)

      HINT: 

      If the depth is more than the maximum, replace the No. 1 chain vibration damper.

  16. 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.

      Standard Thrust Clearance

      0.05 to 0.09 mm (0.00197 to 0.00354 in.)

      Maximum Thrust Clearance

      0.09 mm (0.00354 in.)

      HINT: 

      If the thrust clearance is more than the maximum, replace the engine balancer assembly.

      GTY820692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE 
    1. Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.

      Standard Thrust Clearance

      0.05 to 0.09 mm (0.00197 to 0.00354 in.)

      Maximum Thrust Clearance

      0.09 mm (0.00354 in.)

      HINT: 

      If the thrust clearance is more than the maximum, replace the engine balancer assembly.

      GTY820691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSPECT BALANCE SHAFT BACKLASH 
    1. Secure the No. 3 balance shaft in place, and then using a dial indicator, measure the backlash of the No. 2 balance shaft and No. 3 balance shaft as shown in the illustration.

      Standard Backlash

      0.045 to 0.155 mm (0.00177 to 0.00610 in.)

      Maximum Backlash

      0.155 mm (0.00610 in.)

      NOTE:

      Measure at 3 or more areas around the circumference of the No. 2 balance shaft and No. 3 balance shaft.

      HINT: 

      If the backlash is more than the maximum, replace the engine balancer assembly.

      GTY821775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Secure
  19. INSPECT CYLINDER HEAD SET BOLT 
    1. for 140 mm cylinder head set bolt:
      1. Using a vernier caliper, measure the diameter of the threads at the measurement point.
        GTY766087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Measurement Point
        *b 105 mm (4.134 in.)

        Standard Diameter

        10.7 to 10.9 mm (0.421 to 0.429 in.)

        Minimum Diameter

        10.6 mm (0.417 in.)

        Measurement Point (Distance from the Seat)

        105 mm (0.413 in.)

        HINT: 

        • If the diameter is less than the minimum, replace the cylinder head set bolt with a new one. 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.
    2. for 130 mm cylinder head set bolt:
      1. Using a vernier caliper, measure the diameter of the threads at the measurement point.
        GTY766087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Measurement Point
        *b 115 mm (4.528 in.)

        Standard Diameter

        9.7 to 9.9 mm (0.382 to 0.390 in.)

        Minimum Diameter

        9.6 mm (0.378 in.)

        Measurement Point (Distance from the Seat)

        115 mm (0.374 in.)

        HINT: 

        • If the diameter is less than the minimum, replace the cylinder head set bolt with a new one. 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.
  20. INSPECT EXHAUST MANIFOLD (TWC: Front Catalyst) 
    1. Using a precision straightedge and feeler gauge, check the surface that contacts the cylinder head sub-assembly for warpage.
      GTY809305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum Warpage

      0.7 mm (0.0276 in.)

      HINT: 

      If the warpage is more than the maximum, replace the exhaust manifold (TWC: Front Catalyst).

  21. INSPECT OIL NOZZLE VALVE SUB-ASSEMBLY 
    1. Using a piece of wire, check that the check valve is not stuck.
      GTY764473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 1 mm (0.0394 in.)
      *b 5 mm (0.197 in.)
      *c Check Valve
      *d Wire
      Move the wire in this direction.
      Movement of Check Valve

      HINT: 

      • Form a 1 mm (0.0394 in.) diameter piece of wire to the shape shown in the illustration.
      • If the check valve is stuck, replace the oil nozzle valve sub-assembly with a new one.
    2. GTY762087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hose

      Connect a hose to the oil nozzle valve sub-assembly

    3. Check that air does not leak from the port (B) when blowing air into the port (A).

      HINT: 

      If air leaks from the port (B), replace the oil nozzle valve sub-assembly with a new one.

    4. With the check valve depressed using a piece of wire, check that air flows from the port (B) when blowing air into the port (A).
      GTY741680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hose
      Move the wire in this direction.
      Movement of Check Valve

      HINT: 

      If air does not flow from the port (B), replace the oil nozzle valve sub-assembly with a new one.

    5. Disconnect the hose from the oil nozzle valve sub-assembly.
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