Engine Unit: Inspection

INSPECT BALANCESHAFT THRUST CLEARANCE
1. Install the balanceshafts (See REASSEMBLY ).
2. Using a dial indicator, measure the thrust clearance while moving the balanceshaft back and forth.
  Standard thrust clearance:
  
  0.05 to 0.09 mm (0.0020 to 0.0035 in.)
  
  Maximum thrust clearance:
  
  0.09 mm (0.0035 in.)
  
  If the thrust clearance is greater than the maximum, replace the balanceshaft housing and bearings. If necessary, replace the balanceshaft.
  
  Fig 1: Inspecting Balanceshaft Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT BALANCESHAFT OIL CLEARANCE

Clean each bearing and journal.
Check each bearing and journal for pitting and scratches.
If a bearing or journal is damaged, replace the bearings. If necessary, replace the balanceshaft.
Place the No. 1 and No. 2 balanceshafts onto the crankcase.
Lay a strip of Plastigage across each journal.
Install the balanceshaft housing (See REASSEMBLY ).
NOTE: Do not turn the balanceshafts.
Remove the balanceshafts (See DISASSEMBLY ).

Fig 2: Laying Strip Of Plastigage Across Each Journal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Measure the Plastigage at its widest point.
Standard oil clearance:

0.022 to 0.049 mm (0.0009 to 0.0019 in.)

Maximum oil clearance:

0.049 mm (0.0019 in.)

NOTE: Remove the Plastigage completely after the measurement.

If the oil clearance is greater than the maximum, replace the bearing. If necessary, replace the balanceshaft.

Fig 3: Measuring Plastigage Widest Point
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If replacing a bearing, select a new one with the same number.

Standard Balanceshaft Housing Journal Bore Diameter

BALANCESHAFT HOUSING JOURNAL BORE DIAMETER SPECIFICATION

Item	Specified Condition
Mark 1	26.000 to 26.006 mm (1.0236 to 1.0239 in.)
Mark 2	26.007 to 26.012 mm (1.0239 to 1.0241 in.)
Mark 3	26.013 to 26.018 mm (1.0241 to 1.0243 in.)

Standard Bearing Center Wall Thickness

BEARING CENTER WALL THICKNESS SPECIFICATION

Item	Specified Condition
Mark 1	1.486 to 1.489 mm (0.058S0 to 0.05862 in.)
Mark 2	1.490 to 1.492 mm (0.05866 to 0.05874 in.)
Mark 3	1.493 to 1.495 mm (0.0588 to 0.0589 in.)

Standard balanceshaft journal diameter:

22.985 to 23.000 mm (0.9049 to 0.9055 in.)

Inspect the balanceshaft housing bolts.
1. Using a vernier caliper, measure the length of the bolts from the seat to the end.
  Standard bolt length:
  
  58.3 to 59.7 mm (2.295 to 2.350 in.)
  
  Maximum bolt length:
  
  60.3 mm (2.374 in.)
  
  If the bolt length is greater than the maximum, replace the balanceshaft housing bolt.
  
  Fig 4: Measuring Length Of Bolts From Seat To End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CHAIN SUB-ASSEMBLY
1. Pull the chain with a force of 140 N (14.3 kgf, 31.5 lbf) as shown in the illustration.
2. Using a vernier caliper, measure the length of 15 links.
  Maximum chain elongation:
  
  114.5 mm (4.508 in.)
  
  NOTE: Perform the measurement at 3 random places. Use the average of the measurements.
  
  If the elongation is greater than the maximum, replace the chain.
  
  Fig 5: Measuring Length Of Links
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 CHAIN SUB-ASSEMBLY
1. Pull the chain with a force of 140 N (14.3 kgf, 31.5 lbf) as shown in the illustration.
2. Using a vernier caliper, measure the length of 15 links.
  Maximum chain elongation:
  
  102.2 mm (4.024 in.)
  
  NOTE: Perform the measurement at 3 random places. Use the average of the measurements.
  
  If the elongation is greater than the maximum, replace the No. 2 chain.
  
  Fig 6: Measuring Length Of Links
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT OIL PUMP DRIVE GEAR
1. Place the chain around the sprocket.
2. Using a vernier caliper, measure the sprocket diameter with the chain placed around.
  Minimum gear diameter (with chain):
  
  48.2 mm (1.898 in.)
  
  NOTE: The vernier caliper must be in contact with the chain rollers when measuring.
  
  If the diameter is less than the minimum, replace the chain and sprocket.
  
  Fig 7: Measuring Sprocket Diameter With Chain Placed Around
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT OIL PUMP DRIVE SHAFT GEAR
1. Place the chain around the sprocket.
2. Using a vernier caliper, measure the sprocket diameter with the chain placed around.
  Minimum gear diameter (with chain):
  
  48.2 mm (1.898 in.)
  
  NOTE: The vernier caliper must be in contact with the chain rollers when measuring.
  
  If the diameter is less than the minimum, replace the chain and sprocket.
  
  Fig 8: Measuring Sprocket Diameter With Chain Placed Around
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
1. Place the chain around the sprocket.
2. Using a vernier caliper, measure the sprocket diameter with the chain placed around.
  Minimum gear diameter (with chain):
  
  97.3 mm (3.831 in.)
  
  NOTE: The vernier caliper must be in contact with the chain rollers when measuring.
  
  If the diameter is less than the minimum, replace the chain and sprocket.
  
  Fig 9: Measuring Sprocket Diameter With Chain Placed Around
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
1. Place the chain around the sprocket.
2. Using a vernier caliper, measure the sprocket diameter with the chain placed around.
  Minimum gear diameter (with chain):
  
  97.3 mm (3.831 in.)
  
  NOTE: The vernier caliper must be in contact with the chain rollers when measuring.
  
  If the diameter is less than the minimum, replace the chain and sprocket.
  
  Fig 10: Measuring Sprocket Diameter With Chain Placed Around
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
1. Place the chain around the timing sprocket.
2. Using a vernier caliper, measure the timing gear diameter with the chain placed around.
  Minimum gear diameter (with chain):
  
  51.6 mm (2.031 in.)
  
  NOTE: The vernier caliper must be in contact with the chain rollers when measuring.
  
  If the gear diameter is less than the minimum, replace the chain sub-assembly and crankshaft timing sprocket.
  
  Fig 11: Measuring Sprocket Diameter With Chain Placed Around
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CHAIN TENSIONER SLIPPER
1. Using a vernier caliper, measure the tensioner slipper wear.
  Maximum wear:
  
  1.0 mm (0.039 in.)
  
  If the wear is greater than the maximum, replace the chain tensioner slipper.
  
  Fig 12: Measuring Tensioner Slipper Wear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 CHAIN VIBRATION DAMPER
1. Using a vernier caliper, measure the vibration damper wear.
  Maximum wear:
  
  1.0 mm (0.039 in.)
  
  If the wear is greater than the maximum, replace the No. 1 chain vibration damper.
  
  Fig 13: Measuring Vibration Damper Wear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CHAIN TENSIONER PLATE
1. Using a vernier caliper, measure the chain tensioner plate wear.
  Maximum wear:
  
  0.5 mm (0.020 in.)
  
  If the wear is greater than the maximum, replace the chain tensioner plate.
  
  Fig 14: Measuring Chain Tensioner Plate Wear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY
1. Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.
2. Release the ratchet pawl, then check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
Fig 15: Checking Plunger Moves Smoothly
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 circle runout:
  
  0.03 mm (0.0012 in.)
  
  If the circle runout is greater than the maximum, replace the camshaft.
  
  Fig 16: Measuring Circle Runout At Center Journal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect the cam lobes.
1. Using a micrometer, measure the cam lobe heights.
  Standard cam lobe height:
  
  47.306 to 47.406 mm (1.8624 to 1.8664 in.)
  
  Minimum cam lobe height:
  
  47.196 mm (1.8581 in.)
  
  If any of the cam lobe heights are less than the minimum, replace the camshaft.
  
  Fig 17: Measuring Cam Lobe Heights
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the camshaft journals.

Using a micrometer, measure the journal diameter.

Standard Journal Diameter

JOURNAL DIAMETER SPECIFICATION

Journal Position	Specified Condition
No. 1	35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Others	22.959 to 22.975 mm (0.9039 to 0.9045 in.)

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

Fig 18: Measuring Journal Diameter

INSPECT NO. 2 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 circle runout:
  
  0.03 mm (0.0012 in.)
  
  If the circle runout is greater than the maximum, replace the No. 2 camshaft.
  
  Fig 19: Measuring Circle Runout At Center Journal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect the cam lobes.
1. Using a micrometer, measure the cam lobe heights.
  Standard cam lobe height:
  
  46.063 to 46.163 mm (1.8135 to 1.8174 in.)
  
  Minimum cam lobe height:
  
  45.953 mm (1.8092 in.)
  
  If any of the cam lobe heights are less than the minimum, replace the No. 2 camshaft.
  
  Fig 20: Measuring Cam Lobe Heights
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the camshaft journals.

Using a micrometer, measure the journal diameter.

Standard Journal Diameter

JOURNAL DIAMETER SPECIFICATION

Journal Position	Specified Condition
No. 1	35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Others	22.959 to 22.975 mm (0.9039 to 0.9045 in.)

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

Fig 21: Measuring Journal Diameter