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Inspection [10/2022 - ]: Procedure

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  1. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 
    1. Turn the roller by hand to check that it turns smoothly.
      GTY1077524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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.
    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.
      GTY774574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Correct *b Incorrect
      *c Tapered Path *d Low Pressure Chamber
      *e High Pressure Chamber *f Plunger
      *g Check Ball - -
      • 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

      The plunger moves up and down.

      NOTE:

      When bleeding 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.

    5. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger by hand.

      OK

      The plunger is very difficult to move.

    6. If the plunger moves, bleed the air again.
    7. If the plunger is easy to move, replace the valve lash adjuster assembly.
  3. INSPECT INTAKE CAMSHAFT SUB-ASSEMBLY 
    1. Inspect the intake camshaft sub-assembly for runout.
      GTY1076888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Place the intake camshaft sub-assembly on V-blocks.
      2. Using a dial indicator, measure the runout at the center journal.

        Maximum Runout

        0.03 mm (0.00118 in.)

      3. If the runout is more than the maximum, replace the intake camshaft sub-assembly.
    2. Inspect the cam lobes.
      GTY1076890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a micrometer, measure the cam lobe height.

        Standard Cam Lobe Height

        46.045 to 46.145 mm (1.81279 to 1.81673 in.)

        Minimum Cam Lobe Height

        45.995 mm (1.81082 in.)

      2. If the cam lobe height is less than the minimum, replace the intake camshaft sub-assembly.
    3. Inspect the intake camshaft sub-assembly journals.
      GTY1076883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter

        Item Specified Condition
        No. 1 journal 40.984 to 41.000 mm (1.61354 to 1.61417 in.)
        Other journals 23.959 to 23.975 mm (0.94327 to 0.94390 in.)
      2. If the journal diameter is not as specified, check the intake camshaft sub-assembly oil clearance.
  4. INSPECT EXHAUST CAMSHAFT SUB-ASSEMBLY 
    1. Inspect the exhaust camshaft sub-assembly for runout.
      GTY1076886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Place the exhaust camshaft sub-assembly on V-blocks.
      2. Using a dial indicator, measure the runout at the center journal.

        Maximum Runout

        0.03 mm (0.00118 in.)

      3. If the runout is more than the maximum, replace the exhaust camshaft sub-assembly.
    2. Inspect the cam lobes.
      GTY1076865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a micrometer, measure the cam lobe height.

        Standard Cam Lobe Height

        Item Specified Condition
        Exhaust camshaft sub-assembly 38.489 to 38.589 mm (1.51531 to 1.51925 in.)
        Exhaust camshaft sub-assembly (for Fuel Pump) 49.151 to 49.251 mm (1.93507 to 1.93901 in.)

        Minimum Cam Lobe Height

        Item Specified Condition
        Exhaust camshaft sub-assembly 38.439 mm (1.51334 in.)
        Exhaust camshaft sub-assembly (for Fuel Pump) 49.101 mm (1.93311 in.)
      2. If the cam lobe height is less than the minimum, replace the exhaust camshaft sub-assembly.
    3. Inspect the exhaust camshaft sub-assembly journals.
      GTY1076867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter

        Item Specified Condition
        No. 1 journal 40.984 to 41.000 mm (1.61354 to 1.61417 in.)
        Other journals 23.959 to 23.975 mm (0.94327 to 0.94390 in.)
      2. If the journal diameter is not as specified, check the exhaust camshaft sub-assembly oil clearance.
  5. INSPECT CAMSHAFT OIL CLEARANCE 
    NOTE:

    Do not turn the camshafts.

    1. Clean the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap, No. 4 camshaft bearing cap, No. 5 camshaft bearing cap, camshaft housing sub-assembly and camshaft journals.
    2. Place the intake camshaft sub-assembly and exhaust camshaft sub-assembly on the camshaft housing sub-assembly.
    3. Lay a strip of Plastigage across each of the camshaft journals.
      GTY1076387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
    4. Install the camshaft bearing caps.

      See step  22

    5. Install the camshaft housing sub-assembly.

      See step  23

    6. Remove the camshaft housing sub-assembly.

      See step  44

    7. Remove the camshaft bearing caps.

      See step  45

    8. Measure the Plastigage at its widest point.

      Standard Oil Clearance (for Intake camshaft sub-assembly)

      Item Specified Condition
      No. 1 journal 0.027 to 0.060 mm (0.00106 to 0.00236 in.)
      Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.)

      Standard Oil Clearance (for Exhaust camshaft sub-assembly)

      Item Specified Condition
      No. 1 journal 0.027 to 0.060 mm (0.00106 to 0.00236 in.)
      Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.)

      Maximum Oil Clearance (for Intake camshaft sub-assembly)

      Item Specified Condition
      No. 1 journal 0.075 mm (0.00295 in.)
      Other journals 0.075 mm (0.00295 in.)

      Maximum Oil Clearance (for Exhaust camshaft sub-assembly)

      Item Specified Condition
      No. 1 journal 0.075 mm (0.00295 in.)
      Other journals 0.075 mm (0.00295 in.)
      GTY1077012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastigage
      *b No. 1 Journal
      *c Other Journal
      NOTE:

      Completely remove the Plastigage after the inspection.

    9. If the oil clearance is more than the maximum, replace the intake camshaft sub-assembly or exhaust camshaft sub-assembly. If necessary, replace the camshaft housing sub-assembly.
  6. INSPECT CHAIN SUB-ASSEMBLY 
    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.
      GTY751037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Measurement Length
    2. Using a vernier caliper, measure the length of 15 links.

      Maximum Chain Elongation

      115.78 mm (4.56 in.)

      NOTE:

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

    3. If the average elongation is more than the maximum, replace the chain sub-assembly.
  7. INSPECT OIL PUMP DRIVE CHAIN SUB-ASSEMBLY 
    1. GTY739132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Measurement Length

      Using a spring scale, pull the oil pump drive 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 links.

      Maximum Chain Elongation

      116.35 mm (4.58 in.)

      NOTE:

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

    3. If the average elongation is more than the maximum, replace the oil pump drive chain sub-assembly.
  8. INSPECT OIL PUMP DRIVE SPROCKET 
    1. Place the oil pump drive chain sub-assembly around the oil pump drive sprocket.
      GTY1108078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Chain Roller
    2. Using a vernier caliper, measure the diameter of the oil pump drive sprocket and oil pump drive chain sub-assembly.

      Minimum Sprocket Diameter (with Oil Pump Drive Chain Sub-assembly)

      61.77 mm (2.43 in.)

      NOTE:

      The vernier caliper must be in contact with the chain rollers when measuring.

    3. If the diameter is less than the minimum, replace the oil pump drive chain sub-assembly and oil pump drive sprocket.
  9. INSPECT OIL PUMP DRIVE SHAFT SPROCKET 
    1. Place the oil pump drive chain sub-assembly around the oil pump drive shaft sprocket.
      GTY1107633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Chain Roller
    2. Using a vernier caliper, measure the diameter of the oil pump drive shaft sprocket and oil pump drive chain sub-assembly.

      Minimum Sprocket Diameter (with Oil Pump Drive Chain Sub-assembly)

      51.57 mm (2.03 in.)

      NOTE:

      The vernier caliper must be in contact with the chain rollers when measuring.

    3. If the diameter is less than the minimum, replace the oil pump drive chain sub-assembly and oil pump drive shaft sprocket.
  10. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Place the chain sub-assembly around the camshaft timing gear assembly.
      GTY1104394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Chain Roller
    2. Using a vernier caliper, measure the diameter of the camshaft timing gear assembly and chain sub-assembly.

      Minimum Gear Diameter (with Chain Sub-assembly)

      110.19 mm (4.34 in.)

      NOTE:

      The vernier caliper must be in contact with the chain rollers when measuring.

    3. If the diameter is less than the minimum, replace the chain sub-assembly and camshaft timing gear assembly.
  11. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Place the chain sub-assembly around the camshaft timing exhaust gear assembly.
      GTY1105039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Chain Roller
    2. Using a vernier caliper, measure the diameter of the camshaft timing exhaust gear assembly and chain sub-assembly.

      Minimum Gear Diameter (with Chain Sub-assembly)

      110.19 mm (4.34 in.)

      NOTE:

      The vernier caliper must be in contact with the chain rollers when measuring.

    3. If the diameter is less than the minimum, replace the chain sub-assembly and camshaft timing exhaust gear assembly.
  12. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET 
    1. Place the chain sub-assembly around the crankshaft timing gear or sprocket.
      GTY1107653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Chain Roller
    2. Using a vernier caliper, measure the diameter of the crankshaft timing gear or sprocket and chain sub-assembly.

      Minimum Sprocket Diameter (with Chain Sub-assembly)

      56.68 mm (2.23 in.)

      NOTE:

      The vernier caliper must be in contact with the chain rollers when measuring.

    3. If the diameter is less than the minimum, replace the chain sub-assembly and crankshaft timing gear or sprocket.
  13. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Push the plunger and check that it moves smoothly.
      GTY1076636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plunger
    2. If the plunger does not move smoothly, replace the No. 1 chain tensioner assembly.
  14. INSPECT CHAIN TENSIONER SLIPPER 
    1. Using a vernier caliper, measure the wear depth of the chain tensioner slipper.
      GTY1077303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth

      Maximum Depth

      0.4 mm (0.0157 in.)

      HINT: 

      Wear of the chain tensioner slipper starts from the part where the chain plate of the chain sub-assembly contacts.

    2. If the depth is more than the maximum, replace the chain tensioner slipper.
  15. INSPECT NO. 1 CHAIN VIBRATION DAMPER 
    1. Using a vernier caliper, measure the wear depth of the No. 1 chain vibration damper.
      GTY1076485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth

      Maximum Depth

      0.2 mm (0.00787 in.)

      HINT: 

      Wear of the No. 1 chain vibration damper starts from the part where the chain plate of the chain sub-assembly contacts.

    2. If the depth is more than the maximum, replace the No. 1 chain vibration damper.
  16. INSPECT CHAIN TENSIONER PLATE 
    1. Using a vernier caliper, measure the wear depth of the chain tensioner plate.
      GTY1077002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth

      Maximum Depth

      0.4 mm (0.0157 in.)

      HINT: 

      Wear of the chain tensioner plate starts from the part where the chain plate of the oil pump drive chain sub-assembly contacts.

    2. If the depth is more than the maximum, replace the chain tensioner plate.
  17. INSPECT NO. 2 CHAIN VIBRATION DAMPER 
    1. Using a vernier caliper, measure the wear depth of the No. 2 chain vibration damper.
      GTY1076196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth

      Maximum Depth

      0.2 mm (0.00787 in.)

      HINT: 

      Wear of the No. 2 chain vibration damper starts from the part where the chain plate of the chain sub-assembly contacts.

    2. If the depth is more than the maximum, replace the No. 2 chain vibration damper.
  18. 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.
      GTY1077514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Thrust Clearance

      0.05 to 0.09 mm (0.00197 to 0.00354 in.)

      Maximum Thrust Clearance

      0.15 mm (0.00591 in.)

    2. If the thrust clearance is more than the maximum, replace the engine balancer assembly.
  19. 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.
      GTY1076849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Thrust Clearance

      0.05 to 0.09 mm (0.00197 to 0.00354 in.)

      Maximum Thrust Clearance

      0.15 mm (0.00591 in.)

    2. If the thrust clearance is more than the maximum, replace the engine balancer assembly.
  20. 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.
      GTY1077418Courtesy 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.)

    2. If the backlash is more than the maximum, replace the engine balancer assembly.
  21. INSPECT CYLINDER HEAD SET BOLT 
    1. for 140 mm cylinder head set bolt:
      1. Using a vernier caliper, measure the diameter of the threads at the measurement point.
        GTY766087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Measurement Point
        *b Approximately 105 mm

        Standard Diameter

        10.7 to 10.9 mm (0.421 to 0.429 in.)

        Minimum Diameter

        10.6 mm (0.417 in.)

        Measurement Point (Distance from the Seat)

        Approximately 105 mm (4.13 in.)

      2. If the diameter is less than the minimum, replace the cylinder head set bolt with a new one. Failure to do so may lead to engine damage.
      3. If there is any thread deformation, replace the cylinder head set bolt with a new one.
    2. for 150 mm cylinder head set bolt:
      1. Using a vernier caliper, measure the diameter of the threads at the measurement point.
        GTY766087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Measurement Point
        *b Approximately 115 mm

        Standard Diameter

        11.7 to 11.9 mm (0.461 to 0.469 in.)

        Minimum Diameter

        11.6 mm (0.457 in.)

        Measurement Point (Distance from the Seat)

        Approximately 115 mm (4.53 in.)

      2. If the diameter is less than the minimum, replace the cylinder head set bolt with a new one. Failure to do so may lead to engine damage.
      3. If there is any thread deformation, replace the cylinder head set bolt with a new one.
  22. INSPECT OIL NOZZLE VALVE SUB-ASSEMBLY 
    1. Form a 1.0 mm (0.0394 in.) diameter piece of wire to the shape shown in the illustration.
      GTY764473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 1 mm (0.0394 in.)
      *b 5 mm (0.197 in.)
      *c Check Valve
      *d Wire
      Move the wire in this direction.
      Movement of Check Valve
    2. Using a piece of wire, check that the check valve is not stuck.
    3. GTY762087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hose

      Connect a hose to the oil nozzle valve sub-assembly.

    4. Check that air does not leak from the port (B) when blowing air into the port (A).
    5. With the check valve depressed using a piece of wire, check that air flows from the port (B) when blowing air into the port (A).
      GTY741680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hose
      Move the wire in this direction.
      Movement of Check Valve
    6. Disconnect the hose from the oil nozzle valve sub-assembly.
    7. If the oil nozzle valve sub-assembly is stuck, clogged or leaks, replace it.
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