Inspection [12/2013 - 11/2016]: Procedure

INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

Turn the roller by hand to check that it turns smoothly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.

INSPECT VALVE LASH ADJUSTER ASSEMBLY

NOTE:

Keep the valve lash adjuster assembly free from dirt and foreign matter.
Only use clean engine oil.

Place the valve lash adjuster assembly into a container filled with engine oil.

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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Tapered Path
*b	Plunger
*c	Check Ball
*d	Correct
*e	Incorrect
*f	Low Pressure Chamber
*g	High Pressure Chamber

SST: 09276-75010

Squeeze SST and the valve lash adjuster assembly together to move the plunger up and down 5 to 6 times.
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 in the illustration. If the check ball is not pressed, air will not bleed.
After bleeding the air, remove SST. Then try to quickly and firmly press the plunger by hand.
OK

Plunger is very difficult to move.

If the result is not as specified, replace the valve lash adjuster assembly.

INSPECT CAMSHAFT

Inspect the camshaft for runout.

Place the camshaft on V-blocks.

Using a dial indicator, measure the runout at the center journal.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Maximum Runout

0.04 mm (0.00157 in.)

If the runout is more than the maximum, replace the camshaft.

HINT:

Check the oil clearance after replacing the camshaft.

Using a micrometer, measure the cam lobe height.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard Cam Lobe Height

Item	Specified Condition
Intake camshaft	44.316 to 44.416 mm (1.7448 to 1.7486 in.)
Exhaust camshaft	44.262 to 44.362 mm (1.7426 to 1.7465 in.)

Minimum Cam Lobe Height

Item	Specified Condition
Intake camshaft	44.166 mm (1.7388 in.)
Exhaust camshaft	44.112 mm (1.7366 in.)

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

Using a micrometer, measure the journal diameter.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard Journal Diameter

Item	Specified Condition
No. 1 journal	35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals	25.959 to 25.975 mm (1.0221 to 1.0226 in.)

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

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

Secure the camshaft in a vise.
NOTE:
Be careful not to damage the camshaft in the vise.

Align and fit the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Knock Pin
*b	Pin Hole

Check that there is no gap between the camshaft timing gear assembly flange and the camshaft.

Tighten the bolt while holding the camshaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)

Check the lock of the camshaft timing gear assembly.

Release the lock pin.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Advance Side Path
*b	Retard Side Path
*c	Vinyl Tape
*d	Rubber Piece
*e	Closed
*f	Open

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.
Make a hole in the tape on the advance side path and the retard side path on the opposite side of the groove as shown in the illustration.

Apply approximately 200 kPa (2.0 kgf/cm² , 29 psi) of air pressure to the 2 open paths (the advance side path and the retard side path).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Advance Side Path
*b	Retard Side Path

WARNING:

Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.

Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Advance Side Path
*b	Retard Side Path
*c	Hold Pressure
*d	Decompress

HINT:

The lock pin is released and the camshaft timing gear assembly turns in the advance direction.

When the camshaft timing gear assembly moves to the most advanced position, release the air pressure from the retard side path, and then from the advance side path.
NOTE:
Be sure to release the air pressure from the retard side path first. If the air pressure of the advance side path is released first, the camshaft timing gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.

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 camshaft timing gear assembly turns smoothly.
  NOTE:
  Do not use air pressure to perform the smooth operation check.
Check the lock at the most retarded position.

Remove the bolt and camshaft timing gear assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Knock Pin
*b	Bolt
*c	Do not remove

NOTE:

Do not remove the other 3 bolts.

INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

Clamp the camshaft in a vise.
NOTE:
Be careful not to damage the camshaft in the vise.

Align and fit the knock pin of the camshaft with the pin hole of the camshaft timing exhaust gear assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Knock Pin
*b	Pin Hole

Check that there is no gap between the camshaft timing exhaust gear assembly flange and the camshaft.

Tighten the bolt while holding the camshaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)

Check the lock of the camshaft timing exhaust gear assembly.

Release the lock pin.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Retard Side Path
*b	Advance Side Path
*c	Rubber Piece
*d	Vinyl Tape
*e	Open
*f	Closed

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.
Make a hole in the tape on the advance side path and the retard side path on the opposite side of the groove as shown in the illustration.

Apply approximately 200 kPa (2.0 kgf/cm² , 29 psi) of air pressure to the 2 open paths (the advance side path and the retard side path).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Advance Side Path
*b	Retard Side Path

WARNING:

Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.

Check that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Advance Side Path
*b	Retard Side Path
*c	Decompress
*d	Hold Pressure

HINT:

The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.

When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure from the advance side path, and then 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.

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 advance position. Make sure that the camshaft timing exhaust gear assembly turns smoothly.
  NOTE:
  When the air pressure is released from the advance side path and then from the retard side path, the camshaft timing exhaust 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.
Check the lock at the most advanced position.

Remove the bolt and camshaft timing exhaust gear assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Knock Pin
*b	Bolt
*c	Do not remove

NOTE:

Do not remove the other 4 bolts.

INSPECT CYLINDER HEAD SET BOLT

Using a vernier caliper, measure the diameter of the threads at the measurement point.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Measurement Point

Standard Diameter

10.85 to 11.00 mm (0.4272 to 0.4330 in.)

Minimum Diameter

10.70 mm (0.4212 in.)

Measurement Point (distance from the seat)

103 mm (4.06 in.)

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.

INSPECT CHAIN SUB-ASSEMBLY

Using a spring scale, pull the chain sub-assembly with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Measurement Length

Using a vernier caliper, measure the length of 15 links.
Maximum Chain Elongation

136.9 mm (5.389 in.)

HINT:

Perform the measurement at 3 random places. Use the average of the measurements.

If the average elongation is more than the maximum, replace the chain sub-assembly.

INSPECT NO. 2 CHAIN SUB-ASSEMBLY

Using a spring scale, pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Measurement Length

Using a vernier caliper, measure the length of 15 links.
Maximum Chain Elongation

137.6 mm (5.417 in.)

HINT:

Perform the measurement at 3 random places. Use the average of the measurements.

If the average elongation is more than the maximum, replace the No. 2 chain sub-assembly.

INSPECT CRANKSHAFT TIMING SPROCKET

Place the chain sub-assembly around the crankshaft timing sprocket.

Using a vernier caliper, measure the diameter of the crankshaft timing sprocket with the chain sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Minimum Sprocket Diameter (with Chain)

61.4 mm (2.418 in.)

HINT:

The vernier caliper must contact the chain rollers for the measurement.

If the diameter is less than the minimum, replace the chain sub-assembly and crankshaft timing sprocket.

INSPECT IDLE SPROCKET ASSEMBLY

Place the chain sub-assembly around the idle sprocket assembly.

Using a vernier caliper, measure the diameter of the idle sprocket assembly with the chain sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Minimum Sprocket Diameter (with Chain)

61.4 mm (2.418 in.)

HINT:

The vernier caliper must contact the chain rollers for the measurement.

If the diameter is less than the minimum, replace the chain sub-assembly and idle sprocket assembly.

INSPECT NO. 1 IDLE GEAR SHAFT OIL CLEARANCE

Using a micrometer, measure the diameter of the No. 1 idle gear shaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard No. 1 Idle Gear Shaft Diameter

22.987 to 23.000 mm (0.9050 to 0.9055 in.)

Using a caliper gauge, measure the inside diameter of the idle sprocket assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard Idle Sprocket Assembly Inside Diameter

23.020 to 23.030 mm (0.9063 to 0.9067 in.)

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.)

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

INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

Move the stopper plate clockwise to release the lock. Push the plunger and check that it moves smoothly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Plunger
*b	Stopper Plate

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

INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

Check that the plunger moves smoothly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Depth

Using a vernier caliper, measure the wear depth of the No. 2 chain tensioner assembly.
Maximum Depth

0.9 mm (0.0354 in.)

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

INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY

Check that the plunger moves smoothly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Depth

Using a vernier caliper, measure the wear depth of the No. 3 chain tensioner assembly.
Maximum Depth

0.9 mm (0.0354 in.)

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

INSPECT CHAIN TENSIONER SLIPPER

Measure the wear depth of the chain tensioner slipper.

Depth

Maximum Depth

1.0 mm (0.0394 in.)

If the depth is more than the maximum, replace the chain tensioner slipper.

INSPECT NO. 1 CHAIN VIBRATION DAMPER

Using a vernier caliper, measure the wear depth of the No. 1 chain vibration damper.

Depth

Maximum Depth

1.0 mm (0.0394 in.)

If the depth is more than the maximum, replace the No. 1 chain vibration damper.

INSPECT NO. 2 CHAIN VIBRATION DAMPER

Using a vernier caliper, measure the wear depth of the No. 2 chain vibration damper.

Depth

Maximum Depth

1.0 mm (0.0394 in.)

If the depth is more than the maximum, replace the No. 2 chain vibration damper.

INSPECT CAMSHAFT THRUST CLEARANCE

Inspect the camshaft thrust clearance (for Bank 1).

Install the camshafts.
Refer to PROCEDURE - Step 5

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

Standard Thrust Clearance

0.08 to 0.13 mm (0.00315 to 0.00512 in.)

Maximum Thrust Clearance

0.15 mm (0.00591 in.)

If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly RH. If the thrust surface is damaged, replace the camshaft.

Inspect the camshaft thrust clearance (for Bank 2).
1. Install the camshafts.
  Refer to PROCEDURE - Step 1
2. Using a dial indicator, measure thrust clearance while moving each camshaft back and forth.
  Standard Thrust Clearance
  
  0.08 to 0.13 mm (0.00315 to 0.00512 in.)
  
  Maximum Thrust Clearance
  
  0.15 mm (0.00591 in.)
  
  If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly LH. If the thrust surface is damaged, replace the camshaft.

INSPECT CAMSHAFT OIL CLEARANCE (for Bank 1)

Clean the camshaft bearing caps, camshaft housing sub-assembly RH and camshaft journals.
Place the camshafts on the camshaft housing sub-assembly RH.

Lay a strip of Plastigage across each camshaft journal.

*a	Plastigage

Install the camshaft bearing caps.
Refer to PROCEDURE - Step 7

NOTE:
Do not turn the camshaft.
Remove the camshaft bearing caps.
Refer to PROCEDURE - Step 40

Measure the Plastigage at its widest point.

*a	Plastigage
*b	No. 1 Journal
*c	Other Journals

Standard Oil Clearance

Item	Specified Condition
No. 1 journal	0.032 to 0.063 mm (0.00126 to 0.00248 in.)
Other journals	0.025 to 0.062 mm (0.000984 to 0.00244 in.)

Maximum Oil Clearance

Item	Specified Condition
No. 1 journal	0.10 mm (0.00394 in.)
Other journals	0.09 mm (0.00354 in.)

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

INSPECT CAMSHAFT OIL CLEARANCE (for Bank 2)

Clean the camshaft bearing caps, camshaft housing sub-assembly LH and camshaft journals.
Place the camshafts on the camshaft housing sub-assembly LH.

Lay a strip of Plastigage across each camshaft journal.

*a	Plastigage

Install the camshaft bearing caps.
Refer to PROCEDURE - Step 3

NOTE:
Do not turn the camshaft.
Remove the camshaft bearing caps.
Refer to PROCEDURE - Step 46

Measure the Plastigage at its widest point.

*a	Plastigage
*b	No. 1 Journal
*c	Other Journals

Standard Oil Clearance

Item	Specified Condition
No. 1 journal	0.032 to 0.063 mm (0.00126 to 0.00248 in.)
Other journals	0.025 to 0.062 mm (0.000984 to 0.00244 in.)

Maximum Oil Clearance

Item	Specified Condition
No. 1 journal	0.10 mm (0.00394 in.)
Other journals	0.09 mm (0.00354 in.)

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

INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst)

Using a precision straightedge and feeler gauge, measure the warpage of the surface which contacts the cylinder head sub-assembly LH.

Maximum Warpage

0.7 mm (0.0276 in.)

If the warpage is more than the maximum, replace the exhaust manifold sub-assembly LH (TWC: Front Catalyst).

INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst)

Using a precision straightedge and feeler gauge, measure the warpage of the surface which contacts the cylinder head sub-assembly RH.

Maximum Warpage

0.7 mm (0.0276 in.)

If the warpage is more than the maximum, replace the exhaust manifold sub-assembly RH (TWC: Front Catalyst).

INSPECT INTAKE MANIFOLD

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*A Cylinder Head Side

*B Surge Tank Side
1. Cylinder head side:
  1. Using a precision straightedge and feeler gauge, measure the warpage of the surface which contacts the cylinder head sub-assembly.
    Maximum Warpage
    
    0.1 mm (0.00394 in.)
    
    If the warpage is more than the maximum, replace the intake manifold.
2. Surge tank side:
  1. Using a precision straightedge and feeler gauge, measure the warpage of the surface which contacts the surge tank.
    Maximum Warpage
    
    0.1 mm (0.00394 in.)
    
    If the warpage is more than the maximum, replace the intake manifold.