Inspection [11/2016 - ]: Procedure

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

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 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 any air.
OK

Plunger moves up and down.

NOTE:
When bleeding the air from the high-pressure chamber, make sure that the tip of SST is 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.

HINT:

If the plunger is easy to move, 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.)

HINT:

If the runout is more than the maximum, replace the camshaft.
Check the oil clearance after replacing the camshaft.
See step 17

Using a micrometer, measure the cam lobe height.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard Cam Lobe Height

Item		Specified Condition
Intake camshaft	for Bank 1	44.335 to 44.435 mm (1.74547 to 1.74941 in.)
Intake camshaft	for Bank 2	44.337 to 44.437 mm (1.74555 to 1.74948 in.)
Exhaust camshaft	for Bank 1	43.866 to 43.966 mm (1.72700 to 1.73094 in.)
	for Bank 2	43.867 to 43.967 mm (1.72704 to 1.73098 in.)
	for Fuel Pump	40.554 to 40.654 mm (1.59661 to 1.60055 in.)

Minimum Cam Lobe Height

Item		Specified Condition
Intake camshaft	for Bank 1	44.235 mm (1.74153 in.)
Intake camshaft	for Bank 2	44.237 mm (1.74161 in.)
Exhaust camshaft	for Bank 1	43.766 mm (1.72307 in.)
	for Bank 2	43.767 mm (1.72311 in.)
	for Fuel Pump	40.454 mm (1.59267 in.)

HINT:

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 (1.41519 to 1.41575 in.)
Other journals	25.959 to 25.975 mm (1.02201 to 1.02264 in.)

HINT:

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

See step 17

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
*b	100 mm

Standard Diameter

10.85 to 11.00 mm (0.427 to 0.433 in.)

Minimum Diameter

10.70 mm (0.421 in.)

Measurement Point (Distance from the Seat)

100 mm (3.94 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

137.8 mm (5.43 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

137.8 mm (5.43 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

Maximum Sprocket Diameter (with Chain Sub-assembly)

62.2 mm (2.45 in.)

HINT:

The vernier caliper must contact the chain rollers when measuring.
If the diameter is more than the maximum, 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

Maximum Sprocket Diameter (with Chain Sub-assembly)

65.2 mm (2.57 in.)

HINT:

The vernier caliper must contact the chain rollers when measuring.
If the diameter is more than the maximum, 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 (0.905 to 0.906 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 (0.906 to 0.907 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.)

HINT:

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

Turn 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

HINT:

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

1.0 mm (0.0394 in.)

HINT:

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

1.0 mm (0.0394 in.)

HINT:

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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Depth

Maximum Depth

1.0 mm (0.0394 in.)

HINT:

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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Depth

Maximum Depth

1.0 mm (0.0394 in.)

HINT:

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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Depth

Maximum Depth

1.0 mm (0.0394 in.)

HINT:

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 camshaft.
See step 26
Install the No. 2 camshaft.
See step 27

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

Standard Thrust Clearance

0.08 to 0.130 mm (0.00315 to 0.00512 in.)

Maximum Thrust Clearance

0.18 mm (0.00709 in.)

HINT:

If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly.
If the thrust surface is damaged, replace the camshaft or No. 2 camshaft.

Inspect the camshaft thrust clearance (for Bank 2).
1. Install the No. 3 camshaft sub-assembly.
  See step 14
2. Install the No. 4 camshaft sub-assembly.
  See step 15
3. Using a dial indicator, measure the thrust clearance while moving each camshaft back and forth.
  Standard Thrust Clearance
  
  0.08 to 0.130 mm (0.00315 to 0.00512 in.)
  
  Maximum Thrust Clearance
  
  0.18 mm (0.00709 in.)
  
  HINT:
  - If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly LH.
  - If the thrust surface is damaged, replace the No. 3 camshaft sub-assembly or No. 4 camshaft sub-assembly.

INSPECT CAMSHAFT OIL CLEARANCE

for Bank 1:

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

Lay a strip of Plastigage across each camshaft journal.

*a	Plastigage

Install the camshaft bearing caps.
See step 28

NOTE:
Do not turn the camshaft.
Remove the camshaft bearing caps.
See step 53

Measure the Plastigage at its widest point.

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	0.1 mm (0.00394 in.)
Other journals	0.1 mm (0.00394 in.)

HINT:

If the oil clearance is more than the maximum, replace the camshaft or No. 2 camshaft.
If necessary, replace the camshaft housing sub-assembly.

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

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.
See step 16

NOTE:
Do not turn the camshaft.
Remove the camshaft bearing caps.
See step 59

Measure the Plastigage at its widest point.

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	0.1 mm (0.00394 in.)
Other journals	0.1 mm (0.00394 in.)

HINT:

If the oil clearance is more than the maximum, replace the No. 3 camshaft sub-assembly or No. 4 camshaft sub-assembly.
If necessary, replace the camshaft housing sub-assembly LH.

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

INSPECT INTAKE MANIFOLD

*a	Cylinder Head Side
*b	Surge Tank Side

Cylinder head side:

Using a precision straightedge and feeler gauge, check the surface which contacts the cylinder head sub-assembly and cylinder head LH for warpage.
Maximum Warpage

0.1 mm (0.00394 in.)

HINT:

If the warpage is more than the maximum, replace the intake manifold.

Surge tank side:
1. Using a precision straightedge and feeler gauge, check the surface which contacts the intake air surge tank assembly for warpage.
  Maximum Warpage
  
  0.1 mm (0.00394 in.)
  
  HINT:
  
  If the warpage is more than the maximum, replace the intake manifold.

INSPECT EXHAUST MANIFOLD

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

Maximum Warpage

0.7 mm (0.0276 in.)

HINT:

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