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Inspection [01/2019 - ]: Procedure

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  1. INSPECT CYLINDER HEAD SUB-ASSEMBLY FOR WARPAGE 
    1. Using a precision straightedge and feeler gauge, check the surfaces which contact the cylinder head sub-assembly and manifold for warpage.

      Maximum Warpage

      Item Specified Condition
      Bottom side 0.05 mm (0.00197 in.)
      Intake manifold side 0.10 mm (0.00394 in.)
      Exhaust manifold side 0.10 mm (0.00394 in.)

      HINT: 

      If the warpage is more than the maximum, replace the cylinder head sub-assembly.

      GTY554748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bottom Side
      *b Intake Manifold Side
      *c Exhaust Manifold Side
  2. INSPECT CYLINDER HEAD SUB-ASSEMBLY FOR CRACKS 
    1. Using a dye penetrant, check the intake ports, exhaust ports and bottom surface of the cylinder head sub-assembly for cracks.

      HINT: 

      If cracks are found, replace the cylinder head sub-assembly.

      GTY588159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT INTAKE VALVE 
    1. Using a vernier caliper, measure the overall length of the intake valve.
      GTY595128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Overall Length

      Standard Overall Length

      109.34 mm (4.30 in.)

      Minimum Overall Length

      108.84 mm (4.29 in.)

      HINT: 

      If the overall length is less than the minimum, replace the intake valve.

    2. Using a micrometer, measure the diameter of the valve stem.
      GTY562582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Valve Stem Diameter

      5.470 to 5.485 mm (0.215 to 0.216 in.)

      HINT: 

      If the valve stem diameter is not as specified, check the intake valve guide bush oil clearance.

      See step  6

    3. Using a vernier caliper, measure the valve head margin thickness.

      Standard Margin Thickness

      1.0 mm (0.0394 in.)

      Minimum Margin Thickness

      0.5 mm (0.0197 in.)

      HINT: 

      If the margin thickness is less than the minimum, replace the intake valve.

      GTY549110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Margin Thickness
  4. INSPECT EXHAUST VALVE 
    1. Using a vernier caliper, measure the overall length of the exhaust valve.
      GTY547246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Overall Length

      Standard Overall Length

      108.25 mm (4.26 in.)

      Minimum Overall Length

      107.75 mm (4.24 in.)

      HINT: 

      If the overall length is less than the minimum, replace the exhaust valve.

    2. Using a micrometer, measure the diameter of the valve stem.
      GTY562577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Valve Stem Diameter

      5.465 to 5.480 mm (0.215 to 0.216 in.)

      HINT: 

      If the valve stem diameter is not as specified, check the exhaust valve guide bush oil clearance.

      See step  6

    3. Using a vernier caliper, measure the valve head margin thickness.
      GTY562722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Margin Thickness

      Standard Margin Thickness

      1.0 mm (0.0394 in.)

      Minimum Margin Thickness

      0.5 mm (0.0197 in.)

      HINT: 

      If the margin thickness is less than the minimum, replace the exhaust valve.

  5. INSPECT INNER COMPRESSION SPRING 
    1. Using a vernier caliper, measure the free length of the inner compression spring.

      Standard Free Length

      58.52 mm (2.30 in.) or 58.90 mm (2.32 in.)

      NOTE:

      Inner compression springs come in 2 different lengths. Make sure all inner compression springs are the same length when replacing them.

      GTY588158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a steel square, measure the angle of the inner compression spring.

      Maximum Angle (Reference)

      2°

      GTY542434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Angle
      *b 40 mm (1.57 in.)

      HINT: 

      If the deviation is greater than the maximum, replace the inner compression spring.

  6. INSPECT VALVE GUIDE BUSH OIL CLEARANCE 
    1. Using a caliper gauge, measure the inside diameter of the valve guide bush.
      GTY161253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Valve Guide Bush Inside Diameter

      5.510 to 5.530 mm (0.217 to 0.218 in.)

    2. Subtract the valve stem diameter measurement from the valve guide bush inside diameter measurement.

      Standard Oil Clearance

      Item Specified Condition
      Intake 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
      Exhaust 0.030 to 0.065 mm (0.00118 to 0.00256 in.)

      Maximum Oil Clearance

      Item Specified Condition
      Intake 0.080 mm (0.00315 in.)
      Exhaust 0.085 mm (0.00335 in.)

      HINT: 

      • Oil clearance = Inside diameter - Valve stem diameter
      • If the oil clearance is more than the maximum, replace the valve and valve guide bush.
  7. INSPECT VALVE SEATS 
    1. Apply a light coat of Prussian blue to the valve face.
      GTY592445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Width
    2. Lightly press the valve face against the valve seat.
      NOTE:

      Do not rotate the valve while pressing it.

    3. Check the valve face and valve seat.
      1. If Prussian blue appears 360° around the entire valve face, the valve face is concentric.

        HINT: 

        If the valve face is not concentric, replace the valve.

      2. If Prussian blue appears 360° around the entire valve seat, the valve seat and valve face are concentric.

        HINT: 

        If the valve face is not concentric, resurface the valve seat.

        See step  1

      3. Measure the width of the contact area of the valve seat and valve face.

        Standard Width

        Item Specified Condition
        Intake 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
        Exhaust 1.0 to 1.4 mm (0.0394 to 0.0551 in.)
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