Engine Unit: Inspection

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INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
1. Check the lock of camshaft timing gear.
  1. Clamp the camshaft in a vice, and check that the camshaft timing gear is locked.
    NOTE: Do not damage the camshaft.
2. Release the lock pin.
  1. Cover the 4 oil paths of the cam journal with tape as shown in the illustration.
    HINT:
    
    One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with a piece of rubber before wrapping the cam journal with the tape.
  2. Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path.
    
    Fig 1: Identifying Cam Journal With Tape
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Apply air at about 150 kPa (1.5 kgf*cm² ) pressure into the 2 broken paths (the advance side path and the retard side path).
    NOTE: Cover the paths with a shop rag or piece of cloth to prevent oil splashes.
    
    Fig 2: Applying Air Pressure Advance Side Path And Retard Side Path
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced.
    HINT:
    
    The lock pin is released and the camshaft timing gear revolves in the advance direction.
  5. When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path.
    
    Fig 3: Applying Air Pressure On Advance Side, Side Path Retard Side, Side Path
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    NOTE: Camshaft timing gear assembly occasionally shifts to the retard side abruptly if the air pressure on the advance side path is released first. This often results in breakage of the lock pin.
3. Check that the revolution is smooth.
  1. Rotate the valve timing assembly back and forth several times, except where the lock pin meets it at the most retarded angle. Check the movable range and that it rotates smoothly.
    Standard: Smooth movable range is about 22.5°
    
    NOTE: Perform this check by hand, instead of using air pressure.
4. Check that the gear locks in the most retarded position.
  1. Confirm that the camshaft timing gear assembly is locked in the most retarded position.
INSPECT CHAIN SUB-ASSEMBLY
1. Using a spring scale, apply 140 N (14.3 kgf, 31.5 lb) to the timing chain and measure its length.
  Maximum chain elongation: 123.2 mm (4.850 in.)
  
  If the elongation is greater than the maximum, replace the chain.
  
  HINT:
  
  Perform the same measurement at 3 or more random places and calculate the average length.
  
  Fig 4: Identifying Spring Scale
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CHAIN TENSIONER ASSEMBLY NO. 1
1. Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.
2. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
  
  Fig 5: Releasing Ratchet Pawl
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
1. Wrap the chain around the timing sprocket.
2. Using vernier calipers, measure the diameter of the timing gear with the chain.
  Minimum gear diameter (with chain): 96.2 mm (3.787 in.)
  
  If the diameter is less than the minimum, replace the camshaft timing gear.
  
  NOTE: Make sure that the vernier calipers are in contact with the chain link when measuring.
  
  Fig 6: Measuring Diameter Of Timing Gear With Chain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CAMSHAFT TIMING SPROCKET
1. Wrap the chain around the timing sprocket.
2. Using vernier calipers, measure the diameter of the timing gear with the chain.
  Minimum gear diameter (with chain): 96.2 mm (3.787 in.)
  
  If the diameter is less than the minimum, replace the camshaft timing sprocket.
  
  NOTE: Make sure that the vernier calipers are in contact with the chain link when measuring.
  
  Fig 7: Measuring Diameter Of Timing Gear With Chain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CHAIN TENSIONER SLIPPER
1. Check the chain tensioner slipper.
  Minimum thickness: 1.0 mm (0.039 in.)
  
  If the thickness is less than the minimum, replace the chain tensioner slipper.
  
  Fig 8: Identifying Chain Tensioner Slipper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CHAIN VIBRATION DAMPER NO. 1
1. Check the vibration damper.
  Minimum thickness: 1.0 mm (0.039 in.)
  
  If the thickness is less than the minimum, replace the chain vibration damper.
  
  Fig 9: Identifying Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CONNECTING ROD THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
  Standard thrust clearance: 0.16 to 0.36 mm (0.0063 to 0.0142 in.)
  
  Maximum thrust clearance: 0.36 mm (0.0142 in.)

INSPECT CONNECTING ROD OIL CLEARANCE

Fig 10: Moving Connecting Rod Back And Forth

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
Using SST, remove the 2 connecting rod cap bolts.
SST 09205-16010
Clean the crank pin and bearing.
Check the crank pin and bearing for pitting and scratches.

Fig 11: Removing Connecting Rod Cap Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Lay a strip of Plastigage across the crank pin.

Fig 12: Identifying Plastigage Across Crank Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Make sure that the connecting rod and its cap are in the correct combination and that the front mark of the cap is facing in the correct mounting orientation, then install the cap onto the connecting rod.
Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

Fig 13: Identifying Front Mark Of Connecting Rod
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST, tighten the bolts in several steps to the specified torque.
SST 09205-16010

Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)

Fig 14: Tightening Bolts With SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Mark the front of the connecting cap bolts with paint.
Retighten the cap bolts by 90° as shown in the illustration.

Fig 15: Identifying Mark Of Connecting Cap Bolts With Paint
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Do not turn the crankshaft.
Remove the 2 bolts, connecting rod cap and lower bearing.
Measure the Plastigage at its widest point.
Standard oil clearance: 0.012 to 0.038 mm (0.00047 to 0.00015 in.)

Maximum oil clearance: 0.058 mm (0.0028in.)

NOTE: Completely remove the Plastigage after the measurement.

Fig 16: Removing Plastigage
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

When replacing a bearing, replace it with one with the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked 1, 2 and 3 accordingly.

Standard bearing center wall thickness

BEARING CENTER WALL THICKNESS SPECIFICATIONS

Mark	mm (in.)
1	1.491 to 1.494 (0.0587 to 0.0588)
2	1.494 to 1.497 (0.0588 to 0.0589)
3	1.497 to 1.500 (0.0589 to 0.0591)

Fig 17: Identifying Bearing Marks

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CRANKSHAFT THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the crankshaft back and forth with a screwdriver.
  Standard thrust clearance: 0.09 to 0.19 mm (0.0035 to 0.0075 in.)
  
  Maximum thrust clearance: 0.30 mm (0.0118 in.)
  
  Fig 18: Moving Crankshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Check the crankshaft and block for wear. Repair or replace the parts if necessary.
  
  HINT:
  
  Thrust washer thickness: 2.43 to 2.48 mm (0.0957 to 0.976 in.)
INSPECT CYLINDER BLOCK FOR WARPAGE
1. Using a precision straight edge and feeler gauge, measure the warpage of the surface which is in contact with the cylinder head gasket.
  Maximum warpage: 0.05 mm (0.0020 in.)
  
  Fig 19: Inspecting Cylinder Block For Warpage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER BORE
1. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in both the thrust and axial directions.
  Standard Inside diameter: 75.000 to 75.013 mm (2.9528 to 2.9533 in.)
2. Calculate the difference between the maximum diameter and the minimum diameter of the 4 measured values.
  Difference limit: 0.10 mm (0.0039 in.)
  
  If the difference is greater than the limit, replace the cylinder block.
  
  Fig 20: Measuring Cylinder Bore Diameter Positions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT WITH PIN PISTON SUB-ASSEMBLY
1. Using a micrometer, measure the piston diameter at a right angle to the piston pin center line, and at the position 27.6 to 27.8 mm (1.0866 to 1.0945 in.) from the top of the piston head.
  Piston diameter: 74.935 to 74.945 mm (2.9502 to 2.9506 in.)
2. Using a caliper gauge, measure the piston pin hole diameter.
  Piston pin hole diameter: 18.013 to 18.016 mm (0.7092 to 0.7093 in.) at 20°C (68°F)
  
  Fig 21: Measuring Piston Diameter Right Angle To Piston Pin Center Line
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a micrometer, measure the piston pin diameter.
  Piston pin diameter: 18.001 to 18.004 mm (0.7087 to 0.7088 in.)
4. Subtract the piston pin diameter measurement from the piston pin hole diameter measurement to calculate the oil clearance.
  Standard oil clearance: 0.009 to 0.015 mm (0.0004 to 0.0006 in.)
  
  Maximum oil clearance: 0.050 mm (0.0020 in.)
  
  If necessary, replace the piston and piston pin together.
  
  Fig 22: Measuring Piston Pin Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PISTON CLEARANCE
1. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
  Standard oil clearance: 0.045 to 0.068 mm (0.0018 to 0.0027 in.)
  
  Maximum oil clearance: 0.08 mm (0.0032 in.)
INSPECT CONNECTING ROD SUB-ASSEMBLY
1. Using a rod aligner and feeler gauge, check the connecting rod alignment.
  1. Check for misalignment.
    Maximum misalignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
    
    If the misalignment is greater than the maximum, replace the connecting rod assembly.
    
    Fig 23: Checking Connecting Rod Alignment For Misalignment
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check for twist.
    Maximum twist: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
    
    If the twist is greater than the maximum, replace the connecting rod assembly.
    
    Fig 24: Checking Connecting Rod Alignment For Twist
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT RING GROOVE CLEARANCE
1. Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.
  Ring groove clearance:
  
  No. 1: 0.03 to 0.07 mm (0.0012 to 0.0028 in.)
  
  No. 2: 0.02 to 0.06 mm (0.0008 to 0.0024 in.)
  
  Fig 25: Measuring Clearance Between Piston Ring And Ring Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PISTON RING END GAP
1. Using a piston, push the piston ring, a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block.
  
  Fig 26: Inspecting Piston Ring End Gap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the end gap.
  Standard end gap:
  
  No. 1: 0.25 to 0.35 mm (0.0098 to 0.0138 in.)
  
  No. 2: 0.35 to 0.50 mm (0.0138 to 0.0197 in.)
  
  Oil (Side Rail): 0.10 to 0.35 mm (0.0039 to 0.0138 in.)
  
  Maximum end gap:
  
  No. 1: 0.91 mm (0.0358 in.)
  
  No. 2: 1.06 mm (0.0417 in.)
  
  Oil (Side Rail): 0.82 mm (0.323 in.)
  
  Fig 27: Measuring End Gap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CONNECTING ROD BOLT
1. Using vernier calipers, measure the diameter of the bolt at the elongated portion.
  Standard diameter: 6.6 to 6.7 mm (0.260 to 0.264 in.)
  
  Minimum diameter: 6.4 mm (0.252 in.)
  
  If the diameter is less than the minimum, replace the bolt.
  
  Fig 28: Measuring Diameter Of Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT
1. Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration.
  Maximum circle runout: 0.03 mm (0.0012 in.)
  
  Fig 29: Measuring Circle Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the diameter of each main journal.
  Outside diameter: 45.988 to 46.000 mm (1.8106 to 1.8110 in.)
3. Check each main journal for taper and out-of-roundness as shown.
  Maximum taper and out-of-roundness: 0.02 mm (0.0008 in.)
  
  Fig 30: Identifying Main Journal For Taper And Out-Of-Roundness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a micrometer, measure the diameter of each crank pin.
  Outside diameter: 39.992 to 40.000 mm (1.5745 to 1.5748 in.)
5. Check each crank pin for taper and out-of-roundness as shown.
  Maximum taper and out-of-roundness: 0.02 mm (0.0008 in.)
  
  Fig 31: Identifying Crank Pin For Taper And Out-Of-Roundness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Wrap the chain around the timing sprocket.
7. Using vernier calipers, measure the timing sprocket diameter with the chain.
  Standard sprocket diameter (with chain): 51.72 mm (2.0362 in.)
  
  Minimum sprocket diameter (with chain): 50.5 mm (1.988 in.)
  
  NOTE: Make sure that the vernier calipers are in contact with the chain rollers when measuring.
  
  Fig 32: Measuring Timing Sprocket Diameter With Chain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT BEARING CAP SET BOLT
1. Using vernier calipers, measure the tension portion diameter of the elongated portion.
  Standard diameter: 7.3 to 7.5 mm (0.287 to 0.295 in.)
  
  Minimum diameter: 7.2 mm (0.283 in.)
  
  If the diameter is less than the minimum, replace the bolt.
  
  Fig 33: Measuring Tension Portion Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CRANKSHAFT OIL CLEARANCE

Clean each main journal and bearing.
Install the bearing onto the cylinder block and bearing cap. (See REASSEMBLY )
Place the crankshaft onto the cylinder block.
Lay a strip of Plastigage across each journal.

Fig 34: Identifying Crankshaft Oil Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Examine the front marks and numbers and install the bearing cap onto the cylinder block.
Apply a light coat of engine oil to the threads of the bearing cap bolts.

Fig 35: Identifying Bearing Cap Onto Cylinder Block Marks And Numbers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST, tighten the bolts in several steps to the specified torque in the sequence shown in the illustration. (*1)
SST 09011-38121

Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)

Fig 36: Identifying Crankshaft Bearing Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Mark the front of the bearing cap bolts with paint.
Retighten the bearing cap bolts by 90° in the same sequence as step (*1).
Check that the painted mark is now at a 90° angle from the front.
NOTE: Do not turn the crankshaft.
Remove the bearing cap sub-assembly.

Fig 37: Identifying Mark Of Connecting Cap Bolts With Paint
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Measure the Plastigage at its widest point.
Standard oil clearance: 0.01 to 0.023 mm (0.0004 to 0.0009 in.)

Maximum oil clearance: 0.07 mm (0.0028 in.)

NOTE: Completely remove the Plastigage after the measurement.

Fig 38: Removing Plastigage
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

When replacing a standard bearing, replace it with one with the same number. If the number of the bearing cannot be found, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then select the bearing with the same number as the total. There are 4 sizes of standard bearings, marked 1, 2, 3 and 4 accordingly.

EXAMPLE: Cylinder Block 4 (A) + Crankshaft 3 (B) = Total 7 (Use Bearing 3)

BEARING SPECIFICATIONS

Cylinder Block (A) + Crankshaft (B)	0 to 2	3 to 5	6 to 8	9 to 11
Use Bearing	1	2	3	4

Fig 39: Identifying Bearing Cap Bolts Angle

CYLINDER BLOCK MAIN JOURNAL SPECIFICATIONS

Item	Mark	mm (in.)
Cylinder block main journal bore diameter (A)	0	50.000 to 50.003 (1.96850 to 1.96862)
	1	50.003 to 50.005 (1.96862 to 1.96870)
	2	50.005 to 50.007 (1.96870 to 1.96878)
	3	50.007 to 50.010 (1.96878 to 1.96890)
	4	0.010 to 50.012 (1.96890 to 1.96898)
	5	50.012 to 50.014 (1.96898 to 1.96906)
	6	50.014 to 50.016 (1.96906 to 1.96913)
Crankshaft main journal diameter (B)	0	45.998 to 46.000 (1.81094 to 1.81102)
	1	45.996 to 45.998 (1.81087 to 1.81094)
	2	45.994 to 45.996 (1.81079 to 1.81087)
	3	45.992 to 45.994 (1.81071 to 1.81079)
	4	45.990 to 45.992 (1.81063 to 1.81071)
	5	45.988 to 45.990 (1.81055 to 1.81063)
Standard bearing center wall thickness	1	1.992 to 1.995 (0.07843 to 0.07854)
	2	1.995 to 1.998 (0.07854 to 0.07866)
	3	1.998 to 2.001 (0.07866 to 0.07878)
	4	2.001 to 2.004 (0.07878 to 0.07890)