Engine Unit: Inspection

WARNING: This page is about a different variant/trim than selected.

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 valve rocker arm sub-assembly.
  
  Fig 1: Checking No. 1 Valve Rocker Arm Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT VALVE LASH ADJUSTER ASSEMBLY
NOTE:
- Keep the adjuster free from dirt and foreign matter.
- Use only clean engine oil.
1. Place the lash adjuster into a container full of new engine oil.
2. Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.
  SST 09276-75010
3. Squeeze SST and the lash adjuster 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 high-pressure air from the compression 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 the air, remove SST. Then try to quickly and firmly press the plunger with your fingers.
  OK: Plunger can be pressed 3 times.
  
  If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster with a new one.
  
  Fig 2: Inspecting Valve Lash Adjuster Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CAMSHAFT OIL CLEARANCE (See REPLACEMENT )
INSPECT CAMSHAFT THRUST CLEARANCE (See REPLACEMENT )

INSPECT CAMSHAFT

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.)
  
  If the circle runout is more than the maximum, replace the camshaft sub-assembly.
  
  HINT:
  
  Check the oil clearance after replacing the camshaft.
  
  Fig 3: Measuring Circle Runout At Center Journal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the cam lobes.

Using a micrometer, measure the cam lobe height.

Standard Cam Lobe Height

CAM LOBE HEIGHT SPECIFICATION

Item	Specified Condition
Intake	44.163 to 44.305 mm (1.73870 to 1.74429 in.)
Exhaust	44.144 to 44.286 mm (1.73795 to 1.74354 in.)

Fig 4: Measuring Cam Lobe Height

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Minimum Cam Lobe Height

CAM LOBE HEIGHT SPECIFICATION

Item	Specified Condition
Intake	44.013 mm (1.73279 in.)
Exhaust	43.996 mm (1.73212 in.)

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

Inspect the camshaft journals.

Using a micrometer, measure the journal diameter.

Standard Journal Diameter

JOURNAL DIAMETER SPECIFICATION

Item	Specified Condition
No. 1 journal	34.449 to 34.465 mm (1.35626 to 1.35689 in.)
Other journals	22.959 to 22.975 mm (0.90390 to 0.90453 in.)

Fig 5: Measuring Journal Diameter

If the journal diameter is not as specified, check the oil clearance (See REPLACEMENT ).

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
1. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.
  
  Fig 6: Identifying Knock Pin And Pin Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that there is no clearance between the camshaft timing gear and camshaft flange.
3. Hold the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.
  NOTE: Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.
4. Check the lock of the camshaft timing gear.
  1. Make sure that the camshaft timing gear is locked.
  NOTE: Be careful not to damage the camshaft.
  
  Fig 7: Identifying Clearance Between Camshaft Timing Gear And Camshaft Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Release the lock pin.
  1. Clean the camshaft journal with a non-residue solvent.
  2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
    HINT:
    
    There are 4 oil paths in the grooves of the camshaft. Plug 3 of the paths with pieces of rubber.
  3. Open a hole at port A shown in the illustration.
    
    Fig 8: Covering Oil Paths Of Cam Journal With Vinyl Tape
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. While applying approximately 200 kPa (2.0 kgf/cm² , 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).
  CAUTION: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.
  
  Fig 9: Applying Air Pressure To Oil Path
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.
  
  HINT:
  - The camshaft timing gear assembly may be turned in the advance direction without applying any force.
  - If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.
6. Check for smooth rotation.
  1. Turn the camshaft timing gear within its movable range (26.5 to 28.5°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.
  NOTE: Do not allow the camshaft timing gear assembly to lock.
  
  If it locks, release the lock pin again.
7. Remove the vinyl tape and rubber pieces from the camshaft.
8. Remove the bolt and camshaft timing gear.
INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
1. Align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear.
  
  Fig 10: Identifying No. 2 Camshaft Knock Pin And Camshaft Timing Exhaust Gear Pin Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that there is no clearance between the camshaft timing exhaust gear and camshaft flange.
3. Fix the camshaft in place by hand, and then install the installation bolt of the camshaft timing exhaust gear by hand.
4. Check the lock of the camshaft timing exhaust gear.
  1. Make sure that the camshaft timing exhaust gear is locked.
  NOTE: Be careful not to damage the camshaft.
  
  Fig 11: Identifying Clearance Between Camshaft Timing Exhaust Gear And Camshaft Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Release the lock pin.
  1. Clean the camshaft journal with non-residue solvent.
  2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
    HINT:
    
    There are 4 oil paths in the grooves of the camshaft. Plug 2 paths with rubber pieces.
  3. Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path, as shown in the illustration.
    
    Fig 12: Covering Oil Paths Of Cam Journal With Vinyl Tape
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Apply approximately 200 kPa (2.0 kgf/cm² , 29 psi) of air pressure to the two open paths (the advance side path and retard side path).
    NOTE: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.
    
    Fig 13: Applying Air Pressure To Two Open Paths Advance (Side Path And Retard Side Path)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Check that the camshaft timing exhaust gear 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 turns in the retard direction.
    
    Fig 14: Checking Camshaft Timing Exhaust Gear Turns In Retard Direction
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. When the camshaft timing exhaust gear moves to the most retarded position, release the air pressure 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 may abruptly shift in the advance direction and break the lock pin or other parts.
6. Check for smooth rotation.
  1. Turn the camshaft timing exhaust gear within its movable range (21.5 to 23.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.
  NOTE: When the air pressure is released from the advance side path and then from the retard side path, the gear 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.
7. Check the lock at the most advanced position.
  1. Make sure that the camshaft timing exhaust gear locks at the most advanced position.
8. Remove the vinyl tape and rubber pieces from the camshaft.
9. Remove the bolt and camshaft timing gear.
INSPECT CHAIN SUB-ASSEMBLY
1. Using a spring scale, pull the chain 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 pins.
  Maximum chain elongation:
  
  137.7 mm (5.42 in.)
  
  HINT:
  
  Perform the measurement at 3 random places. If the elongation is more than the maximum, replace the chain sub-assembly.
  
  Fig 15: Measuring Length Of Chain Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT TIMING SPROCKET
1. Place the chain around the sprocket.
2. Using a vernier caliper, measure the sprocket diameter with the chain.
  Minimum sprocket diameter (with chain):
  
  59.94 mm (2.36 in.)
  
  If the diameter is less than the minimum, replace the chain and crankshaft timing sprocket.
  
  HINT:
  
  The vernier caliper must contact the chain rollers for the measurement.
  
  Fig 16: Measuring Chain Elongation
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY
1. Move the stopper plate counterclockwise to release the lock. Push the plunger and check that it moves smoothly.
  If necessary, replace the No. 1 chain tensioner assembly.
  
  Fig 17: Inspecting No. 1 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 (0.0394 in.)
  
  If the depth is more than the maximum, replace the chain tensioner slipper.
  
  Fig 18: Identifying Worn Depth Of Chain Tensioner Slipper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 CHAIN VIBRATION DAMPER
1. Measure the worn depth of the chain vibration damper.
  Maximum depth: 1.0 mm (0.0394 in.)
  
  If the depth is more than the maximum, replace the No. 1 chain vibration damper.
  
  Fig 19: Identifying Worn Depth Of Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TIMING CHAIN GUIDE
1. Measure the worn depth of the timing chain guide.
  Maximum depth: 1.0 mm (0.0394 in.)
  
  If the depth is more than the maximum, replace the timing chain guide.
  
  Fig 20: Identifying Worn Depth Of Timing Chain Guide
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.)
  
  If the thrust clearance is more than the maximum, replace the engine balancer assembly.
  
  Fig 21: Measuring No. 1 Balance Shaft Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the No. 2 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.)
  
  If the thrust clearance is more than the maximum, replace the engine balancer assembly.
  
  Fig 22: Measuring No. 2 Balance Shaft Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT BALANCE SHAFT BACKLASH
1. Hold the No. 2 balance shaft in place, and then using a dial indicator, measure the backlash of the No. 1 and No. 2 balance shafts as shown in the illustration.
  Standard backlash:
  
  0.04 to 0.17 mm (0.00157 to 0.00669 in.)
  
  Maximum backlash:
  
  0.17 m (0.00669 in.)
  
  NOTE: Measure at 3 or more areas around the circumference of the No. 1 and No. 2 balance shafts.
  
  Fig 23: Measuring Backlash Of No. 1 And No. 2 Balance Shafts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the backlash is more than the maximum, replace the engine balancer assembly.
INSPECT CYLINDER HEAD BOLT
1. Using a vernier caliper, measure the diameter of the threads at the measurement point.
  Standard diameter:
  
  10.85 to 11.00 mm (0.427 to 0.433 in.)
  
  Minimum diameter:
  
  10.6 mm (0.417 in.)
  
  Measurement point (distance from the seat):
  
  106 mm (4.17 in.)
  
  Fig 24: Identifying Measurement Point Of Cylinder Head Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  - If the diameter is less than the minimum, replace the cylinder head bolt. Failure to do so may lead to engine damage.
  - If there is any thread deformation, replace the cylinder head bolt with a new one.
INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
1. Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts the cylinder head.
  Maximum warpage: 0.7 mm (0.0276 in.)
  
  If the warpage is more than the maximum, replace the exhaust manifold.
  
  Fig 25: Measuring Warpage Of Exhaust Manifold Converter Surface
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002