Inspection [12/2022 - ]: Procedure

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

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

INSPECT INTAKE CAMSHAFT SUB-ASSEMBLY

Inspect the intake camshaft sub-assembly for runout.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Place the intake camshaft sub-assembly on V-blocks.

Using a dial indicator, measure the runout at the center journal.

Maximum Runout

Specified Condition	Result
0.03 mm 0.00118 in.	mm in.

If the runout is more than the maximum, replace the intake camshaft sub-assembly.

Inspect the cam lobes.

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Using a micrometer, measure the cam lobe height.

Standard Cam Lobe Height

Minimum Cam Lobe Height	Specified Condition	Result
42.157 mm 1.65972 in.	42.267 to 42.367 mm 1.66405 to 1.66799 in.	mm in.

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

Inspect the intake camshaft sub-assembly journals.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the journal diameter.

Standard Journal Diameter

Item	Specified Condition	Result
No. 1 journal	33.984 to 34.000 mm 1.33795 to 1.33858 in.	mm in.
Other journals	23.959 to 23.975 mm 0.94327 to 0.94390 in.	mm in.

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

INSPECT EXHAUST CAMSHAFT SUB-ASSEMBLY

Inspect the exhaust camshaft sub-assembly for runout.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Place the exhaust camshaft sub-assembly on V-blocks.

Using a dial indicator, measure the runout at the center journal.

Maximum Runout

Specified Condition	Result
0.03 mm 0.00118 in.	mm in.

If the runout is more than the maximum, replace the exhaust camshaft sub-assembly.

Inspect the cam lobes.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the cam lobe height.

Standard Cam Lobe Height

Item	Minimum Cam Lobe Height	Specified Condition	Result
Exhaust camshaft sub-assembly	42.052 mm 1.65559 in.	42.162 to 42.262 mm 1.65992 to 1.66385 in.	mm in.
Exhaust camshaft sub-assembly (for Fuel Pump)	42.836 mm 1.68645 in.	42.946 to 43.046 mm 1.69078 to 1.69472 in.	mm in.

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

Inspect the exhaust camshaft sub-assembly journals.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the journal diameter.

Standard Journal Diameter

Item	Specified Condition	Result
No. 1 journal	40.984 to 41.000 mm 1.61354 to 1.61417 in.	mm in.
Other journals	23.959 to 23.975 mm 0.94327 to 0.94390 in.	mm in.

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

INSPECT CAMSHAFT OIL CLEARANCE

NOTE:

Do not turn the camshafts.

Pre-procedure1

Clean the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 2 No. 3 camshaft bearing caps, No. 4 camshaft bearing cap, camshaft housing sub-assembly and camshaft journals.
Place the intake camshaft sub-assembly and exhaust camshaft sub-assembly on the camshaft housing sub-assembly.

Lay a strip of Plastigage across each of the camshaft journals.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Plastigage

Install the camshaft bearing caps.
HINT:

See step 24
Install the camshaft housing sub-assembly.
HINT:

See step 25
Remove the camshaft housing sub-assembly.
HINT:

See step 39
Remove the camshaft bearing caps.
HINT:

See step 40

Measure the Plastigage at its widest point.

Standard Oil Clearance (for Intake camshaft sub-assembly)

Item	Maximum Oil Clearance	Specified Condition	Result
No. 1 Journal	0.085 mm 0.00335 in.	0.035 to 0.072 mm 0.00138 to 0.00283 in.	mm in.
Other Journals	0.085 mm 0.00335 in.	0.025 to 0.062 mm 0.000984 to 0.00244 in.	mm in.

Standard Oil Clearance (for Exhaust camshaft sub-assembly)

Item	Maximum Oil Clearance	Specified Condition	Result
No. 1 Journal	0.085 mm 0.00335 in.	0.027 to 0.064 mm 0.00106 to 0.00252 in.	mm in.
Other Journals	0.085 mm 0.00335 in.	0.025 to 0.062 mm 0.000984 to 0.00244 in.	mm in.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

NOTE:

Completely remove the Plastigage after the inspection.

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.

Post-procedure1

None

INSPECT CHAIN SUB-ASSEMBLY

Pre-procedure1

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

Specified Condition	Result
116.30 mm 4.58 in.	mm 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.

Post-procedure1

None

INSPECT OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

Pre-procedure1

Courtesy 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.

Using a vernier caliper, measure the length of 15 links.

Maximum Chain Elongation

Specified Condition	Result
116.30 mm 4.58 in.	mm 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 oil pump drive chain sub-assembly.

Post-procedure1

None

INSPECT OIL PUMP DRIVE SPROCKET

Pre-procedure1

Place the oil pump drive chain sub-assembly around the oil pump drive sprocket.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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)

Specified Condition	Result
51.35 mm 2.02 in.	mm in.

NOTE:

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

If the diameter is less than the minimum, replace the oil pump drive chain sub-assembly and oil pump drive sprocket.

Post-procedure1

None

INSPECT OIL PUMP DRIVE SHAFT SPROCKET

Pre-procedure1

Place the oil pump drive chain sub-assembly around the oil pump drive shaft sprocket.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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)

Specified Condition	Result
51.35 mm 2.02 in.	mm in.

NOTE:

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

If the diameter is less than the minimum, replace the oil pump drive chain sub-assembly and oil pump drive shaft sprocket.

Post-procedure1

None

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

Pre-procedure1

Place the chain sub-assembly around the camshaft timing gear assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a vernier caliper, measure the diameter of the camshaft timing gear assembly and chain sub-assembly.

Minimum Gear Diameter (with Chain Sub-assembly)

Specified Condition	Result
100.01 mm 3.94 in.	mm in.

NOTE:

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

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

Post-procedure1

None

INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

Pre-procedure1

Place the chain sub-assembly around the camshaft timing exhaust gear assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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)

Specified Condition	Result
100.01 mm 3.94 in.	mm in.

NOTE:

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

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

Post-procedure1

None

INSPECT CRANKSHAFT TIMING SPROCKET

Pre-procedure1

Place the chain sub-assembly around the crankshaft timing sprocket.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a vernier caliper, measure the diameter of the crankshaft timing sprocket and chain sub-assembly.

Minimum Sprocket Diameter (with Chain Sub-assembly)

Specified Condition	Result
51.35 mm 2.02 in.	mm in.

NOTE:

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

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

Post-procedure1

None

INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

Push the plunger and check that it moves smoothly.

Plunger

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

INSPECT CHAIN TENSIONER SLIPPER

Using a vernier caliper, measure the wear depth of the chain tensioner slipper.

Depth

Maximum Depth

Specified Condition	Result
1.0 mm 0.0394 in.	mm in.

HINT:

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

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.

Depth

Maximum Depth

Specified Condition	Result
1.0 mm 0.0394 in.	mm in.

HINT:

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

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

INSPECT CYLINDER HEAD SET BOLT

for 140 mm cylinder head set bolt:

Using a vernier caliper, measure the diameter of the threads at the measurement point.

*a	Measurement Point
*b	105 mm

Standard Diameter

Measurement Point (Distance from the Seat)	Minimum Diameter	Specified Condition	Result
105 mm 4.13 in.	10.6 mm 0.417 in.	10.7 to 10.9 mm 0.421 to 0.429 in.	mm in.

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.

for 130 mm cylinder head set bolt:

Using a vernier caliper, measure the diameter of the threads at the measurement point.

*a	Measurement Point
*b	115 mm

Standard Diameter

Measurement Point (Distance from the Seat)	Minimum Diameter	Specified Condition	Result
115 mm 4.53 in.	9.6 mm 0.378 in.	9.7 to 9.9 mm 0.382 to 0.390 in.	mm in.

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.

INSPECT EXHAUST MANIFOLD (TWC: Front Catalyst)

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

Maximum Warpage

Specified Condition	Result
0.7 mm 0.0276 in.	mm in.

If the warpage is more than the maximum, replace the exhaust manifold (TWC: Front Catalyst).

INSPECT OIL NOZZLE VALVE SUB-ASSEMBLY

Pre-procedure1

Form a 1.0 mm (0.0394 in.) diameter piece of wire to the shape shown in the illustration.

*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

Using a piece of wire, check that the check valve is not stuck.

Pre-procedure2

Hose

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

Check that air does not leak from the port (B) when blowing air into the port (A).

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).

*a	Hose
	Move the wire in this direction.
	Movement of Check Valve

Post-procedure1

Disconnect the hose from the oil nozzle valve sub-assembly.
If the oil nozzle valve sub-assembly is stuck, clogged or leaks, replace it.