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Inspection [12/2013 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Turn the roller by hand to check that it turns smoothly.
      GTY131103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

  2. INSPECT VALVE LASH ADJUSTER ASSEMBLY 
    NOTE:
    • Keep the valve lash adjuster assembly free from dirt and foreign matter.
    • Only use clean engine oil.
    GTY445326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Correct *b Incorrect
    *c Taper *d Low Pressure Chamber
    *e High Pressure Chamber *f Plunger
    *g Check Ball - -
    1. Place the valve lash adjuster assembly into a container filled with engine oil.
    2. 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.
      • SST: 09276-75010 
    3. Squeeze SST and the 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 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 by hand.

      OK

      Plunger is very difficult to move.

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

  3. INSPECT CAMSHAFT OIL CLEARANCE 

    See step  8

  4. INSPECT CAMSHAFT THRUST CLEARANCE 

    See step  9

  5. INSPECT CAMSHAFT 
    1. Inspect the camshaft for runout.
      GTY184433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Place the camshaft on V-blocks.
      2. Using a dial indicator, measure the runout at the center journal.

        Maximum Runout

        0.03 mm (0.00118 in.)

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

        HINT: 

        Check the oil clearance after replacing the camshaft.

    2. Inspect the cam lobes.
      GTY184431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a micrometer, measure the cam lobe height.

        Standard Cam Lobe Height

        Item Specified Condition
        Intake camshaft 44.163 to 44.305 mm (1.739 to 1.744 in.)
        Exhaust camshaft 44.144 to 44.286 mm (1.738 to 1.744 in.)

        Minimum Cam Lobe Height

        Item Specified Condition
        Intake camshaft 44.013 mm (1.733 in.)
        Exhaust camshaft 43.996 mm (1.732 in.)

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

    3. Inspect the camshaft journals.
      GTY195099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter

        Item Specified Condition
        No. 1 journal 34.449 to 34.465 mm (1.356 to 1.357 in.)
        Other journals 22.959 to 22.975 mm (0.904 to 0.905 in.)

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

        See step  8

  6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Secure the camshaft in a vise.
      NOTE:

      Be careful not to damage the camshaft in the vise.

    2. Align and fit the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.
      GTY442562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin
      *b Pin Hole
    3. Check that there is no gap between the camshaft timing gear assembly and camshaft flange.
      GTY443876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Gap
      *d No Gap
    4. Secure the camshaft in place by hand, and then install the bolt of the camshaft timing gear assembly by hand.

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      NOTE:

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    5. Check the lock of the camshaft timing gear assembly.
      1. Make sure that the camshaft timing gear assembly is locked.
        NOTE:

        Be careful not to damage the camshaft.

    6. Release the lock pin.
      GTY450135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retard Side Path *b Advance Side Path
      *c Open *d Close
      *e Rubber Piece *f Vinyl Tape
      *g Knock 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 3 of the paths with rubber pieces.

      3. Make a hole at the port (A) shown in the illustration.
      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).
        GTY383765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        WARNING:

        Cover the path with a piece of cloth when applying pressure to keep oil from spraying.

        NOTE:

        Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

        HINT: 

        • Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.
        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.
    7. Check for smooth rotation.
      1. Turn the camshaft timing gear assembly within its movable range (19 to 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 allow the camshaft timing gear assembly to lock.

        If it locks, release the lock pin again.

    8. Remove the vinyl tape and rubber pieces from the camshaft.
    9. Remove the bolt and camshaft timing gear assembly.
  7. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Secure the camshaft in a vise.
      NOTE:

      Be careful not to damage the camshaft in the vise.

    2. Align and fit the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.
      GTY439573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin
      *b Pin Hole
    3. Check that there is no gap between the camshaft timing exhaust gear assembly and camshaft flange.
      GTY443877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Gap
      *d No Gap
    4. Secure the No. 2 camshaft in place by hand, and then install the bolt of the camshaft timing exhaust gear assembly by hand.

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      NOTE:

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    5. Check the lock of the camshaft timing exhaust gear assembly.
      1. Make sure that the camshaft timing exhaust gear assembly is locked.
        NOTE:

        Be careful not to damage the No. 2 camshaft.

    6. Release the lock pin.
      GTY432223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retard Side Path *b Advance Side Path
      *c Open *d Close
      *e Rubber Piece *f Vinyl Tape
      *g Knock 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 No. 2 camshaft. Plug 2 paths with rubber pieces.

      3. Make a hole in the tape placed on the advance side path. Make 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.
      4. Apply approximately 200 kPa (2.0 kgf/cm2 , 29 psi) of air pressure to the 2 open paths (the advance side path and retard side path).
        GTY449773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retard Side Path
        *b Advance Side Path
        WARNING:

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

      5. Check that the camshaft timing exhaust gear assembly turns in the retard direction when reducing the air pressure applied to the advance side path.
        GTY454623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retard Side Path
        *b Advance Side Path
        *c Hold Pressure
        *d Decompress

        HINT: 

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

      6. 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.

    7. Check for smooth rotation.
      1. Turn the camshaft timing exhaust gear assembly within its movable range (19 to 21°) 2 or 3 times, but do not turn it to the most advanced 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.

    8. Check the lock at the most advanced position.
      1. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position.
    9. Remove the vinyl tape and rubber pieces from the No. 2 camshaft.
    10. Remove the bolt and camshaft timing exhaust gear assembly.
  8. INSPECT CHAIN SUB-ASSEMBLY 
    GTY452899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Measurement Length
    1. 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.
    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. Use the average of the measurements.

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

  9. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET 
    1. Place the chain sub-assembly around the crankshaft timing sprocket.
    2. Using a vernier caliper, measure the crankshaft timing sprocket diameter with the chain sub-assembly.

      Minimum Sprocket Diameter (with Chain)

      59.94 mm (2.36 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.

      GTY177435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. 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.
      GTY453804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plunger
      *b Stopper Plate

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

  11. INSPECT CHAIN TENSIONER SLIPPER 
    1. Measure the wear depth of the chain tensioner slipper.
      GTY442705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth

      Maximum Depth

      1.0 mm (0.0394 in.)

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

  12. INSPECT NO. 1 CHAIN VIBRATION DAMPER 
    1. Measure the wear depth of the No. 1 chain vibration damper.
      GTY446443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth

      Maximum Depth

      1.0 mm (0.0394 in.)

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

  13. INSPECT TIMING CHAIN GUIDE 
    1. Measure the wear depth of the timing chain guide.
      GTY447785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth

      Maximum Depth

      1.0 mm (0.0394 in.)

      If the depth is more than the maximum, replace the timing chain guide.

  14. 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.
      GTY184317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

  15. 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.
      GTY195134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

  16. INSPECT BALANCE SHAFT BACKLASH 
    1. Secure the No. 2 balance shaft in place, and then using a dial indicator, measure the backlash of the No. 1 balance shaft and No. 2 balance shaft as shown in the illustration.
      GTY449573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Secure

      Standard Backlash

      0.04 to 0.17 mm (0.00157 to 0.00669 in.)

      Maximum Backlash

      0.17 mm (0.00669 in.)

      NOTE:

      Measure at 3 or more areas around the circumference of the No. 1 balance shaft and No. 2 balance shaft.

      If the backlash is more than the maximum, replace the engine balancer assembly.

  17. INSPECT CYLINDER HEAD BOLT 
    1. Using a vernier caliper, measure the diameter of the threads at the measurement point.
      GTY441854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 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.)

      HINT: 

      • If the diameter is less than the minimum, replace the cylinder head bolt with a new one. Failure to do so may lead to engine damage.
      • If there is any thread deformation, replace the cylinder head bolt with a new one.
  18. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY 
    1. Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts the cylinder head sub-assembly.
      GTY195074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum Warpage

      0.7 mm (0.0276 in.)

      If the warpage is more than the maximum, replace the exhaust manifold sub-assembly.

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