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Inspection [12/2021 - ]: Procedure

  1. INSPECT VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Turn the roller by hand to check that it turns smoothly.
      GTY653370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      If the roller does not turn smoothly, replace the valve rocker arm sub-assembly.

  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 
      GTY674910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Correct *b Incorrect
      *c Tapered Path *d Plunger
      *e Low Pressure Chamber *f Check Ball
      *g High Pressure Chamber - -
    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 can be pressed 3 times.

      HINT: 

      If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster assembly 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

        0.03 mm (0.00118 in.)

        HINT: 

        • If the runout is more than the maximum, replace the camshaft.
        • Check the oil clearance after replacing the camshaft.

          See step  22

        GTY965054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a micrometer, measure the cam lobe height.

      Standard Cam Lobe Height

      Item Specified Condition
      Intake camshaft for Bank 1 42.619 to 42.719 mm (1.67791 to 1.68184 in.)
      for Bank 2 42.619 to 42.719 mm (1.67791 to 1.68184 in.)
      Exhaust camshaft for Bank 1 38.539 to 38.639 mm (1.51728 to 1.52121 in.)
      for Bank 2 38.539 to 38.639 mm (1.51728 to 1.52121 in.)
      for Fuel Pump 35.550 to 35.650 mm (1.39960 to 1.40354 in.)

      Minimum Cam Lobe Height

      Item Specified Condition
      Intake camshaft for Bank 1 42.559 mm (1.67554 in.)
      for Bank 2 42.559 mm (1.67554 in.)
      Exhaust camshaft for Bank 1 38.479 mm (1.51491 in.)
      for Bank 2 38.479 mm (1.51491 in.)
      for Fuel Pump 35.490 mm (1.3972 in.)

      HINT: 

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

      GTY965061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a micrometer, measure the journal diameter.

      Standard Journal Diameter

      Item Specified Condition
      No. 1 Journal for Intake Side 40.984 to 41.000 mm (1.61354 to 1.61417 in.)
      for Exhaust Side 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 oil clearance.

      8See step  22

  4. INSPECT CYLINDER HEAD SET BOLT 
    1. Using a vernier caliper, measure the diameter of the threads at the measurement point.
      GTY1066598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt A
      *b Bolt B
      *c Measurement Point
      *d 115 mm (4.52 in.)
      *e 105 mm (4.13 in.)

      Standard Diameter

      for bolt A 

      11.760 to 11.972 mm (0.463 to 0.471 in.)

      for bolt B 

      10.794 to 10.974 mm (0.425 to 0.432 in.)

      Minimum Diameter

      for bolt A 

      11.60 mm (0.457 in.) less than

      for bolt B 

      10.60 mm (0.417 in.) less than

      HINT: 

      • 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.
  5. INSPECT NO. 1 CHAIN SUB-ASSEMBLY 
    1. Using a spring scale, pull the No. 1 chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) and measure the length of the chain using a vernier caliper.
      GTY818936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Measurement Area

      Maximum chain elongation

      137.38 mm (5.40 in.)

      HINT: 

      Perform the measurement at 3 random places. If a measurement is more than the maximum, replace the No. 1 chain sub-assembly.

  6. INSPECT NO. 2 CHAIN SUB-ASSEMBLY 
    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 chain using a vernier caliper.

      Maximum chain elongation

      115.72 mm (4.55 in.)

      HINT: 

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

      GTY836895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Measurement Area
  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

      116.35 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.
      GTY813312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a vernier caliper, measure the diameter of the oil pump drive sprocket with the oil pump drive chain sub-assembly.

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

      62.39 mm (2.45 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.
      GTY813310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a vernier caliper, measure the diameter of the oil pump drive shaft sprocket with the oil pump drive chain sub-assembly.

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

      57.31 mm (2.25 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 INTAKE GEAR ASSEMBLY 
    1. GTY965063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for No. 1 Chain Sub-assembly Side:

      1. Place the No. 1 chain sub-assembly around the camshaft timing intake gear assembly.
      2. Using a vernier caliper, measure the diameter of the camshaft timing intake gear assembly with the No. 1 chain sub-assembly.

        Minimum Gear Diameter (with No. 1 Chain Sub-assembly)

        113.74 mm (4.47 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 No. 1 chain sub-assembly and camshaft timing intake gear assembly.

    2. GTY965060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for No. 2 Chain Sub-assembly Side:

      1. Place the No. 2 chain sub-assembly around the camshaft timing intake gear assembly.
      2. Using a vernier caliper, measure the diameter of the camshaft timing intake gear assembly with the No. 2 chain sub-assembly.

        Minimum Gear Diameter (with No. 2 Chain Sub-assembly)

        74.55 mm (2.93 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 No. 2 chain sub-assembly and camshaft timing intake gear assembly.

  11. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Place the No. 2 chain sub-assembly around the camshaft timing exhaust gear assembly.
      GTY965062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a vernier caliper, measure the diameter of the camshaft timing exhaust gear assembly with the No. 2 chain sub-assembly.

      Minimum Gear Diameter (with No. 2 Chain Sub-assembly)

      75.01 mm (2.95 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 No. 2 chain sub-assembly and camshaft timing exhaust gear assembly.

  12. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET 
    1. Place the No. 1 chain sub-assembly around the crankshaft timing gear or sprocket.
    2. Using a vernier caliper, measure the diameter of the crankshaft timing gear or sprocket with the No. 1 chain sub-assembly.
      GTY813312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Minimum Sprocket Diameter (with No. 1 Chain Sub-assembly)

      59.76 mm (2.35 in.)

      NOTE:

      The vernier caliper must contact the chain rollers when measuring.

      HINT: 

      If the diameter is less than the minimum, replace the No. 1 chain sub-assembly and crankshaft timing gear or sprocket.

  13. INSPECT IDLE SPROCKET ASSEMBLY 
    1. Place the No. 1 chain sub-assembly around the idle sprocket assembly.
    2. Using a vernier caliper, measure the diameter of the idle sprocket assembly with the No. 1 chain sub-assembly.
      GTY681491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Minimum Sprocket Diameter (with No. 1 Chain Sub-assembly)

      65.8 mm (2.59 in.)

      NOTE:

      The vernier caliper must contact the chain rollers when measuring.

      HINT: 

      If the diameter is less than the minimum, replace the No. 1 chain sub-assembly and idle sprocket assembly.

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

      Standard No. 1 idle gear shaft diameter

      22.987 to 23.000 mm (0.905 to 0.906 in.)

      GTY653298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a caliper gauge, measure the inside diameter of the idle sprocket assembly.

      Standard idle sprocket assembly inside diameter

      23.020 to 23.030 mm (0.906 to 0.907 in.)

      GTY653299Courtesy 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 (0.000787 to 0.00169 in.)

      Maximum oil clearance

      0.093 mm (0.00366 in.)

      HINT: 

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

  15. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Turn the stopper plate clockwise to release the lock. Push the plunger and check that it moves smoothly.
      GTY836728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plunger
      *b Stopper Plate

      HINT: 

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

  16. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY 
    1. Check that the plunger moves smoothly.
      GTY785888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth
    2. Using a vernier caliper, measure the wear depth of the No. 2 chain tensioner assembly.

      Maximum Depth

      1.0 mm (0.0394 in.)

      HINT: 

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

  17. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY 
    1. Check that the plunger moves smoothly.
      GTY777370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth
    2. Using a vernier caliper, measure the wear depth of the No. 3 chain tensioner assembly.

      Maximum Depth

      1.0 mm (0.0394 in.)

      HINT: 

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

  18. INSPECT CHAIN TENSIONER SLIPPER 
    1. Measure the wear depth of the chain tensioner slipper.
      GTY829406Courtesy 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.

  19. INSPECT NO. 1 CHAIN VIBRATION DAMPER 
    1. Measure the wear depth of the No. 1 chain vibration damper.
      GTY965438Courtesy 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.

  20. INSPECT NO. 2 CHAIN VIBRATION DAMPER 
    1. Using a vernier caliper, measure the wear depth of the No. 2 chain vibration damper.
      GTY798194Courtesy 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. 2 chain vibration damper.

  21. INSPECT CAMSHAFT THRUST CLEARANCE 
    1. Inspect the camshaft thrust clearance (for Bank 1).
      1. Install the intake camshaft sub-assembly RH.

        Refer to PROCEDURE - Step 15

      2. Install the exhaust camshaft sub-assembly RH.

        Refer to PROCEDURE - Step 16

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

        Standard Thrust Clearance

        0.06 to 0.20 mm (0.00236 to 0.00787 in.)

        Maximum Thrust Clearance

        0.25 mm (0.00984 in.)

        HINT: 

        • If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly RH.
        • If the thrust surface is damaged, replace the intake camshaft sub-assembly RH or exhaust camshaft sub-assembly RH.
        GTY965064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Inspect the camshaft thrust clearance (for Bank 2).
      1. Install the intake camshaft sub-assembly LH.

        Refer to PROCEDURE - Step 8

      2. Install the exhaust camshaft sub-assembly LH.

        Refer to PROCEDURE - Step 9

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

        Standard Thrust Clearance

        0.06 to 0.20 mm (0.00236 to 0.00787 in.)

        Maximum Thrust Clearance

        0.25 mm (0.00984 in.)

        HINT: 

        • If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly LH.
        • If the thrust surface is damaged, replace the intake camshaft sub-assembly LH or exhaust camshaft sub-assembly LH.
  22. 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 onto the camshaft housing sub-assembly RH.
      3. Lay a strip of Plastigage across each camshaft journal.
        GTY965617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Plastigage
      4. Install the camshaft bearing caps.

        Refer to PROCEDURE - Step 16

        NOTE:

        Do not turn the camshaft.

      5. Remove the camshaft bearing caps.

        Refer to PROCEDURE - Step 58

      6. Measure the Plastigage at its widest point.
        GTY965341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Plastigage
        *b No. 1 Journal
        *c Other Journals

        Standard Oil Clearance

        Item Specified Condition
        No. 1 journal 0.035 to 0.072 mm (0.00137 to 0.00283 in.)
        Other journals 0.025 to 0.057 mm (0.000984 to 0.00224 in.)

        Maximum Oil Clearance

        Item Specified Condition
        No. 1 journal 0.085 mm (0.00334 in.)
        Other journals 0.085 mm (0.00334 in.)

        HINT: 

        • If the oil clearance is more than the maximum, replace the intake camshaft sub-assembly RH or exhaust camshaft sub-assembly RH.
        • If necessary, 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 onto the camshaft housing sub-assembly LH.
      3. Lay a strip of Plastigage across each camshaft journal.
        GTY965512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Plastigage
      4. Install the camshaft bearing caps.

        Refer to PROCEDURE - Step 6

        NOTE:

        Do not turn the camshaft.

      5. Remove the camshaft bearing caps.

        Refer to PROCEDURE - Step 67

      6. Measure the Plastigage at its widest point.
        GTY965275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Plastigage
        *b No. 1 Journal
        *c Other Journals

        Standard Oil Clearance

        Item Specified Condition
        No. 1 journal 0.035 to 0.072 mm (0.00137 to 0.00283 in.)
        Other journals 0.025 to 0.057 mm (0.000984 to 0.00224 in.)

        Maximum Oil Clearance

        Item Specified Condition
        No. 1 journal 0.085 mm (0.00334 in.)
        Other journals 0.085 mm (0.00334 in.)

        HINT: 

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