Engine Unit: Inspection

INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Turn the roller by hand to check that it turns smoothly.
  HINT:
  
  If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.
  
  Fig 1: Turning Roller
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 SST's tip into the valve lash adjuster assembly's plunger and use the tip to press down on the check ball inside the plunger.
  SST 09276-75010
3. Squeeze SST and 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 actually pressing the check ball as shown below. 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 with by hand.
  OK: Plunger is very difficult to move.
  
  If the result is not as specified, replace the valve lash adjuster assembly.
  
  Fig 2: Pressing Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CAMSHAFT

Inspect the camshaft for runout.
1. Place the camshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
  Maximum runout: 0.04 mm (0.0016 in.)
  
  If the runout is greater than the maximum, replace the camshaft.
  
  HINT:
  
  Check the oil clearance after replacing the camshaft.
  
  Fig 3: Measuring Circle Runout At Center Journal Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the cam lobe height.

Standard cam lobe height

CAM LOBE HEIGHT SPECIFICATION

Item	Specification
Intake camshaft	44.316 to 44.416 mm (1.7447 to 1.7487 in.)
Exhaust camshaft	44.262 to 44.362 mm (1.7426 to 1.7465 in.)

Maximum cam lobe height

CAM LOBE HEIGHT SPECIFICATION

Item	Specification
Intake camshaft	44.166 mm (1.7388 in.)
Exhaust camshaft	44.112 mm (1.7367 in.)

Fig 4: Measuring Cam Lobe Height Using Micrometer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the journal diameter.

Standard 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.

Fig 5: Measuring Journal Diameter Using Micrometer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
1. Clamp the camshaft in a vise.
  NOTE: Be careful not to damage the camshaft in the vise.
2. Put the camshaft timing gear assembly and camshaft together by aligning the key groove and straight pin.
  
  Fig 6: Aligning Key Groove & Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Lightly press and turn the camshaft timing gear assembly against the camshaft, press harder after the pin enters the groove.
  NOTE: Be sure not to turn the camshaft timing gear assembly in the retard direction.
4. Check that there is no clearance between the camshaft timing gear assembly's flange and the camshaft.
5. Tighten the flange bolt with the camshaft timing gear assembly fixed.
  Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
6. Check the lock of the camshaft timing gear assembly.
  1. Clamp the camshaft in a vise, and confirm that the camshaft timing gear assembly is locked.
    NOTE: Be careful not to damage the camshaft.
    
    Fig 7: Checking Lock Of Camshaft Timing Gear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Release the lock pin.
  1. Cover the 4 oil paths of the cam journal with vinyl tape as shown below.
    HINT:
    
    The 2 advance side paths are located in the camshaft grove. Plug one of the paths with a rubber piece.
    
    Fig 8: Covering Oil Paths Of Cam Journal With Vinyl Tape
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path.
  3. Apply approximately 200 kPa (2.0 kgf/cm² , 28 psi) of air pressure to the 2 opened paths.
    CAUTION: Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.
    
    Fig 9: Applying Air Pressure To Two Broken Paths
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path.
    HINT:
    
    This operation releases the lock pin for the most retarded position.
    
    Fig 10: Checking Camshaft Timing Gear Revolves In Advance Direction
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure first from the retard side path and next from advance side path.
    NOTE: Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.
8. Check for smooth rotation.
  1. Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.
    NOTE: Do not use air pressure to perform the smooth operation check.
9. Check the lock in the most retarded position.
  1. Confirm that the camshaft timing gear assembly locks at the most retarded position.
10. Remove the flange bolt and camshaft timing gear assembly.
  NOTE:
  - Do not remove the other 3 bolts.
  - If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear.
  Fig 11: Identifying Flange Bolt & Camshaft Timing Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
1. Clamp the camshaft in a vise.
  NOTE: Be careful not to damage the camshaft in the vise.
2. Put the camshaft timing exhaust gear assembly and camshaft together by aligning the key groove and straight pin.
  
  Fig 12: Aligning Key Groove & Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Lightly press and turn the camshaft timing gear assembly against the camshaft, press harder after the pin enters the groove.
  NOTE: Be sure not to turn the camshaft timing exhaust gear in the retard direction.
4. Check that there is no clearance between the gear's flange and the camshaft.
5. Tighten the flange bolt with the camshaft timing exhaust gear assembly fixed.
  Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
6. Check the camshaft timing exhaust gear lock.
  1. Make sure that the camshaft timing exhaust gear assembly locks.
7. Release the lock pin.
  1. Cover the 4 oil paths of the cam journal with vinyl tape as shown below.
    HINT:
    
    The 2 advance side paths are located in the camshaft grove. Plug one of the paths with a rubber piece.
    
    Fig 14: Covering Oil Paths Of Cam Journal With Vinyl Tape
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path.
  3. Apply approximately 200 kPa (2.0 kgf/cm² , 28 psi) of air pressure to the 2 opened paths (the advance side path and the retard side path).
    CAUTION: Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.
    
    Fig 15: Applying Air Pressure To Broken Paths
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Make sure that the camshaft timing exhaust gear assembly turns in the retard direction when reducing the air pressure applied to the advance side path.
    HINT:
    
    The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.
  5. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure first from the advance side path, and then release the air pressure from the retard side path.
    NOTE: Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.
    
    Fig 16: Checking Camshaft Timing Exhaust Gear Turns In Retard Direction
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Check for smooth rotation.
  1. Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear assembly turns smoothly.
    NOTE: When the air pressure is released from the advance side path and then from the retard side path, the gear assembly automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.
9. Check the lock at the most advanced position.
  1. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position.
10. Remove the flange bolt and camshaft timing exhaust gear assembly.
  NOTE:
  - Be sure not to remove the other 4 bolts.
  - If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.
  Fig 17: Identifying Flange Bolts & Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER HEAD SET BOLT
1. Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point.
  Standard outside diameter: 10.85 to 11.00 mm (0.4272 to 0.4331 in.)
  
  Minimum outside diameter: 10.70 mm (0.4213 in.)
  
  Measuring point: 103 mm (4.06 in.)
  
  HINT:
  
  If a visual check reveals no excessively thin areas, check the center of the bolt and find the area that has the lowest diameter.
  
  If the diameter is less than the minimum, replace the cylinder head set bolt.
  
  Fig 18: Measuring Minimum Diameter Of Elongated Thread At Measuring Point Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CHAIN SUB-ASSEMBLY
1. Pull the chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) as shown below.
2. Using vernier calipers, measure the length of 15 links.
  Maximum chain elongation: 136.9 mm (5.390 in.)
  
  NOTE: Perform the measurement at 3 random places. Use the average of the measurements.
  
  If the average elongation is greater than the maximum, replace the chain sub-assembly.
  
  Fig 19: Measuring Length Of Chain Links Using Vernier Caliper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 CHAIN SUB-ASSEMBLY
1. Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown below.
2. Using vernier calipers, measure the length of 15 links.
  Maximum chain elongation: 137.6 mm (5.417 in.)
  
  NOTE: Perform the measurement at 3 random places. Use the average of the measurements.
  
  If the average elongation is greater than the maximum, replace the chain sub-assembly.
  
  Fig 20: Measuring No. 2 Chain Sub-Assembly Links Length Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT TIMING SPROCKET
1. Wrap the chain around the sprocket.
2. Using vernier calipers, measure the sprocket diameter with the chain sub-assembly.
  Minimum sprocket diameter (with chain): 61.4 mm (2.417 in.)
  
  HINT:
  
  The vernier calipers must contact the chain rollers for the measurement.
  
  If the diameter is less than the minimum, replace the chain and sprocket.
  
  Fig 21: Measuring Sprocket Diameter With Chain Sub-Assembly Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT IDLE SPROCKET ASSEMBLY
1. Wrap the chain around the sprocket.
2. Using vernier calipers, measure the sprocket diameter with the chain.
  Minimum sprocket diameter (with chain): 61.4 mm (2.417 in.)
  
  HINT:
  
  The vernier calipers must contact the chain rollers for the measurement.
  
  If the diameter is less than the minimum, replace the chain and sprocket.
  
  Fig 22: Measuring Sprocket Diameter With Chain Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT IDLE GEAR SHAFT OIL CLEARANCE
1. Using a micrometer, measure the idle gear shaft diameter.
  Idle gear shaft diameter: 22.987 to 23.000 mm (0.9050 to 0.9055 in.)
  
  Fig 23: Measuring Idle Gear Shaft Diameter Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a caliper gauge, measure the inside diameter of the idle sprocket assembly.
  Idle gear inside diameter: 23.020 to 23.030 mm (0.9063 to 0.9067 in.)
  
  Fig 24: Measuring Inside Diameter Of Idle Sprocket Assembly Using Caliper Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Subtract the idle gear shaft diameter measurement from the idle sprocket inside diameter measurement.
  Standard oil clearance: 0.020 to 0.043 mm (0.0008 to 0.0017 in.)
  
  Maximum oil clearance: 0.093 mm (0.0037 in.)
  
  If the thrust oil clearance is greater than the maximum, replace the idle gear shaft and idle sprocket assembly.
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.
  
  Fig 25: Moving Stopper Plate Upward To Release Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
1. Check that the plunger moves smoothly.
2. Measure the worn depth of the No. 2 chain tensioner assembly.
  Maximum depth: 0.9 mm (0.035 in.)
  
  If the depth is greater than the maximum, replace the No. 2 chain tensioner assembly.
  
  Fig 26: Identifying Worn Depth Of No. 2 Chain Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY
1. Check that the plunger moves smoothly.
2. Measure the worn depth of the No. 3 chain tensioner assembly.
  Maximum depth: 0.9 mm (0.035 in.)
  
  If the depth is greater than the maximum, replace the No. 3 chain tensioner assembly.
  
  Fig 27: Identifying Worn Depth Of No. 3 Chain Tensioner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CHAIN TENSIONER SLIPPER
1. Measure the worn depth of the chain tensioner slipper.
  Maximum depth: 1.0 mm (0.039 in.)
  
  If the depth is greater than the maximum, replace the chain tensioner slipper.
  
  Fig 28: Identifying Worn Depth Of Chain Tensioner Slipper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 CHAIN VIBRATION PAMPER
1. Measure the worn depth of the No. 1 chain vibration damper.
  Maximum depth: 1.0 mm (0.039 in.)
  
  If the depth is greater than the maximum, replace the No. 1 chain vibration damper.
  
  Fig 29: Identifying Worn Depth Of No. 1 Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 CHAIN VIBRATION DAMPER
1. Measure the worn depth of the No. 2 chain vibration damper.
  Maximum depth: 1.0 mm (0.039 in.)
  
  If the depth is greater than the maximum, replace the No. 2 chain vibration damper.
  
  Fig 30: Identifying Worn Depth Of No. 2 Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CAMSHAFT THRUST CLEARANCE
1. Inspect the bank 1 camshaft thrust clearance.
  1. Install the bank 1 camshaft (See INSTALLATION ).
  2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
    Standard thrust clearance: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
    
    Maximum thrust clearance: 0.15 mm (0.006 in.)
    
    If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.
    
    Fig 31: Measuring Camshaft Thrust Clearance Using Dial Indicator
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect the bank 2 camshaft thrust clearance.
  1. Install the bank 2 camshaft (See INSTALLATION ).
  2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
    Standard thrust clearance: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
    
    Maximum thrust clearance: 0.15 mm (0.006 in.)
    
    If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

INSPECT CAMSHAFT OIL CLEARANCE

Clean the camshaft bearing caps, camshaft housing and camshaft journals.
Place the camshafts on the camshaft housing.
Lay a strip of Plastigage across each of the camshaft journals.
Install the camshaft bearing caps (See REASSEMBLY for Bank 1 , REASSEMBLY for Bank 2 ).
NOTE: Do not turn the camshaft.
Remove the camshaft bearing caps (See DISASSEMBLY for Bank 1 , DISASSEMBLY for Bank 2 ).

Fig 32: Checking Camshaft Oil Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Measure the Plastigage at its widest point.

Standard oil clearance

OIL CLEARANCE SPECIFICATION

Item	Oil Clearance
No. 1 journal	0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journals	0.025 to 0.062 mm (0.00098 to 0.0024 in.)

Maximum oil clearance

OIL CLEARANCE SPECIFICATION

Item	Oil Clearance
No. 1 journal	0.10 mm (0.0039 in.)
Other journals	0.09 mm (0.0035 in.)

If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.

Fig 33: Measuring Plastigage At Camshaft Widest Point

Clean the camshaft bearing caps, camshaft housing and camshaft journals.
Place the camshafts on the camshaft housing.
Lay a strip of Plastigage across each camshaft journal.

Fig 34: Laying Strip Of Plastigage Across Each Of Camshaft Journals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the camshaft bearing caps (See REASSEMBLY for Bank 1 , REASSEMBLY for Bank 2 ).
NOTE: Do not turn the camshaft.
Remove the camshaft bearing caps (See DISASSEMBLY for Bank 1 , DISASSEMBLY for Bank 2) .

Measure the Plastigage at its widest point.

Standard oil clearance

OIL CLEARANCE SPECIFICATION

Item	Oil Clearance
No. 1 journal	0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journals	0.025 to 0.062 mm (0.00098 to 0.0024 in.)

Maximum oil clearance

OIL CLEARANCE SPECIFICATION

Item	Oil Clearance
No. 1 journal	0.10 mm (0.0039 in.)
Other journals	0.09 mm (0.0035 in.)

If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing sub-assembly.

Fig 35: Measuring Plastigage At Camshaft Widest Point