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Inspection [09/2022 - ]: 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.
      GTY772103Courtesy 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.
    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.

      HINT: 

      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.
      GTY1019376Courtesy 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.)

        HINT: 

        • If the runout is more than the maximum, replace the intake camshaft sub-assembly.
        • Check the intake camshaft sub-assembly oil clearance after replacing the intake camshaft sub-assembly.
    2. Inspect the cam lobes.
      GTY1019384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a micrometer, measure the cam lobe height.

        Standard Cam Lobe Height

        38.303 to 38.403 mm (1.508 to 1.512 in.)

        Minimum Cam Lobe Height

        38.193 mm (1.5037in.)

        HINT: 

        If the cam lobe height is less than the minimum, replace the intake camshaft sub-assembly.

    3. Inspect the intake camshaft sub-assembly journals.
      GTY1019380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter

        Item Specified Condition
        No. 1 journal 40.967 to 40.983 mm (1.6129 to 1.6135 in.)
        Other journals 23.958 to 23.968 mm (0.94322 to 0.9436 in.)
  4. INSPECT EXHAUST CAMSHAFT SUB-ASSEMBLY 
    1. Inspect the exhaust camshaft sub-assembly for runout.
      GTY1020372Courtesy 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.)

        HINT: 

        • If the runout is more than the maximum, replace the exhaust camshaft sub-assembly.
        • Check the camshaft oil clearance after replacing the exhaust camshaft sub-assembly.
    2. Inspect the cam lobes.
      GTY1019369Courtesy 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 38.572 to 38.672 mm (1.519 to 1.523 in.)
        Exhaust camshaft sub-assembly (for Fuel Pump) 39.550 to 39.650 mm (1.557 to 1.561 in.)

        Minimum Cam Lobe Height

        Item Specified Condition
        Exhaust camshaft sub-assembly 38.462 mm (1.5142 in.)
        Exhaust camshaft sub-assembly (for Fuel Pump) 39.440 mm (1.5570 in.)

        HINT: 

        If the cam lobe height is less than the minimum, replace the exhaust camshaft sub-assembly.

    3. Inspect the exhaust camshaft sub-assembly journals.
      GTY1019368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter

        Item Specified Condition
        No. 1 journal 40.967 to 40.983 mm (1.613 to 1.614 in.)
        Other journals 23.958 to 23.968 mm (0.943 to 0.944 in.)
  5. 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

      137.6 mm (5.4173 in.)

      NOTE:

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

      HINT: 

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

  6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY 
    GTY1019371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Place the chain sub-assembly around the camshaft timing gear assembly.
    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)

      114.09 mm (4.49 in.)

      NOTE:

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

      HINT: 

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

  7. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    GTY1019370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Place the chain sub-assembly around the camshaft timing exhaust gear assembly.
    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)

      114.09 mm (4.49 in.)

      NOTE:

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

      HINT: 

      If the diameter is less than the minimum, replace the chain sub-assembly and camshaft timing exhaust gear assembly.

  8. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET 
    1. Place the chain sub-assembly around the crankshaft timing gear or sprocket.
      GTY1019373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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)

      51.35 mm (2.02 in.)

      NOTE:

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

      HINT: 

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

  9. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Push the plunger and check that it moves smoothly.
      GTY1020261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plunger

      HINT: 

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

  10. INSPECT CHAIN TENSIONER SLIPPER 
    1. Using a vernier caliper, measure the wear depth of the chain tensioner slipper.
      GTY1019757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth

      Maximum Depth

      1.0 mm (0.0394 in.)

      HINT: 

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

  11. INSPECT NO. 1 CHAIN VIBRATION DAMPER 
    1. Using a vernier caliper, measure the wear depth of the No. 1 chain vibration damper.
      GTY1020223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 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.

  12. INSPECT CYLINDER HEAD SET BOLT 
    1. for M11 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 105 mm (4.134 in.)

        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)

        105 mm (4.134 in.)

        HINT: 

        • 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.
        • If there is any thread deformation, replace the cylinder head set bolt with a new one.
    2. for M12 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 115 mm (4.528 in.)

        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)

        115 mm (4.528 in.)

        HINT: 

        • 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.
        • If there is any thread deformation, replace the cylinder head set bolt with a new one.
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