Engine Unit: Inspection

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INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Turn the roller by hand to check that it turns smoothly.
  HINT:
  
  If the roller does not turn smoothly, replace the valve rocker arm sub-assembly.
Fig 1: Turning Roller By Hand For Checking Smoothly Turns
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT VALVE LASH ADJUSTER ASSEMBLY
NOTE:
- Keep the lash adjuster free of dirt and foreign objects.
- Only use clean engine oil.
1. Place the lash adjuster into a container filled with engine oil.
2. Insert the SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.
  SST 09276-75010
3. Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
4. Check the movement of the plunger and bleed the air.
  OK:
  
  Plunger moves up and down.
  
  NOTE: When bleeding air from the high-pressure chamber, make sure that the tip of the SST is actually 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 the SST. Then try to quickly and firmly press the plunger with a finger.
  OK:
  
  Plunger is very difficult to move.
  
  If the result is not as specified, replace the lash adjuster.
Fig 2: Checking Movement Of Plunger And Bleed Air
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CAMSHAFT

Inspect the camshaft for runout.
1. Place the camshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
  Maximum circle runout:
  
  0.04 mm (0.0016 in.)
  
  If the circle runout is greater than the maximum, replace the camshaft.
  
  HINT:
  
  Check the oil clearance after replacing the camshaft.
  
  Fig 3: Measuring Circle Runout At Center Journal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the cam lobe height.

Standard cam lobe height

CAM LOBE HEIGHT SPECIFICATION

Item	Specification
Intake camshaft	44.316 to 44.416 mm (1.7447 to 1.7487 in.)
Exhaust camshaft	44.262 to 44.362 mm (1.7426 to 1.7465 in.)

Maximum cam lobe height

CAM LOBE HEIGHT SPECIFICATION

Item	Specification
Intake camshaft	44.166 mm (1.7388 in.)
Exhaust camshaft	44.112 mm (1.7367 in.)

Fig 4: Checking Cam Lobe Height

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the journal diameter.

Standard journal diameter

STANDARD JOURNAL DIAMETER SPECIFICATION

Item	Specification
No. 1 journal	35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journals	25.959 to 25. 975 mm (1.0220 to 1.0226 in.)

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

Fig 5: Checking Journal Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
1. Clamp the camshaft in a vise.
  NOTE: Be careful not to damage the camshaft in the vise.
2. Put the camshaft timing gear and camshaft together by aligning the key groove and straight pin.
3. Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.
  NOTE: Be sure not to turn the camshaft timing gear in the retard direction (the right angle).
4. Check that there is no clearance between the gear's flange and the camshaft.
  
  Fig 6: Aligning Key Groove And Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Tighten the flange bolt with the camshaft timing gear fixed.
  Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
6. Check the lock of the camshaft timing gear.
  1. Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked.
    NOTE: Be careful not to damage the camshaft.
    
    Fig 7: Checking Lock Of Camshaft Timing Gear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Release the lock pin.
  1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
    HINT:
    
    2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece.
  2. Break through the tape of the advance side path and the retard side path on the opposite side to the hole of the advance side path, as shown in the illustration.
    
    Fig 8: Covering Oil Paths Of Cam Journal With Vinyl Tape
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Apply approximately 200 kPa (2.0 kgf/cm² , 28 psi) of air pressure to the 2 broken paths.
    CAUTION: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.
    
    Fig 9: Applying Pressure To Keep Oil From Splashing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path.
    HINT:
    
    This operation releases the lock pin for the most retarded position.
  5. When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path in that order.
    NOTE: do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.
    
    Fig 10: Applying Pressure To Keep Oil From Splashing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Check for smooth rotation.
  1. Turn the camshaft timing gear within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.
    NOTE: do not use air pressure to perform the smooth operation check.
9. Check the lock in the most retarded position.
  1. Confirm that the camshaft timing gear is locked at the most retarded position.
10. Remove the flange bolt and camshaft timing gear.
  NOTE:
  - Do not remove the other 3 bolts.
  - If the gear will be reused, be sure to release the straight pin lock before installing the gear.
  Fig 11: Identifying Camshaft Timing Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
1. Clamp the camshaft in a vise.
  NOTE: Be careful not to damage the camshaft in the vise.
2. Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and straight pin.
3. Lightly press the gear against the camshaft and turn the gear. Push further at the position where the pin enters the groove.
  NOTE: Be sure not to turn the camshaft timing exhaust gear in the retard direction (the right angle).
4. Check that there is no clearance between the gear's flange and the camshaft.
  
  Fig 12: Aligning Key Groove And Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Tighten the flange bolt with the camshaft timing exhaust gear fixed.
  Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
6. Check the camshaft timing exhaust gear lock.
  1. Make sure that the camshaft timing exhaust gear is locked.
    
    Fig 13: Checking Camshaft Timing Exhaust Gear Lock
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Release the lock pin.
  1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
    HINT:
    
    4 oil paths are provided in the groove. Plug 2 paths with rubber pieces.
  2. Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path, as shown in the illustration.
    
    Fig 14: Covering Oil Paths Of Cam Journal With Vinyl Tape
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Apply approximately 200 kPa (2.0 kgf/cm² , 28 psi) of air pressure to the 2 broken paths (the advance side path and the retard side path).
    CAUTION: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.
    
    Fig 15: Applying Air Pressure To Two Broken Paths
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Make sure that the camshaft timing exhaust gear turns in the retard direction when reducing the air pressure applied to the advance side path.
    HINT:
    
    The lock pin is released and the camshaft timing exhaust gear turns in the retard direction.
    
    Fig 16: Checking Camshaft Timing Exhaust Gear Turns In Retard Direction
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. When the camshaft timing exhaust gear moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path.
    NOTE: Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear may abruptly shift in the advance direction and break the lock pin or other parts.
8. Check for smooth rotation.
  1. Turn the camshaft timing exhaust gear within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.
    NOTE: When the air pressure is released from the advance side path and then from the retard side path, the gear automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.
9. Check the lock at the most advanced position.
  1. Make sure that the camshaft timing exhaust gear is locked at the most advanced position.
10. Remove the flange bolt and camshaft timing exhaust gear.
  NOTE:
  - Be sure not to remove the other 4 bolts.
  - If the gear will be reused, be sure to release the straight pin lock before installing the gear.
    
    Fig 17: Identifying Flange Bolt And Camshaft Timing Exhaust Gear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER HEADSET BOLT
1. Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point.
  Standard outside diameter:
  
  10.85 to 11.00 mm (0.4272 to 0.4331 in.)
  
  Minimum outside diameter:
  
  10.70 mm (0.4213 in.)
  
  Measuring Point:
  
  103 mm (4.06 in.)
  
  HINT:
  
  If no excessively thin areas are found in a visual check, check the center of the bolt and find the area that has the lowest diameter.
  
  If the diameter is less than the minimum, replace the cylinder head bolt.
  
  Fig 18: Measuring Cylinder Head Bolt Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CHAIN SUB-ASSEMBLY
1. Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.
2. Using vernier calipers, measure the length of 15 links.
  Maximum chain elongation:
  
  136.9 mm (5.390 in.)
  
  NOTE: Perform the measurement at 3 random places. Use the average of the measurements.
  
  If the elongation is greater than the maximum, replace the chain.
  
  Fig 19: Measuring Chain Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 CHAIN SUB-ASSEMBLY
1. Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.
2. Using vernier calipers, measure the length of 15 links.
  Maximum chain elongation:
  
  137.6 mm (5.417 in.)
  
  NOTE: Perform the measurement at 3 random places. Use the average of the measurements.
  
  If the elongation is greater than the maximum, replace the chain.
  
  Fig 20: Measuring No. 2 Chain Sub-Assembly Links Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT TIMING SPROCKET
1. Wrap the chain around the sprocket.
2. Using vernier calipers, measure the sprocket diameter with the chain.
  Minimum sprocket diameter (with chain):
  
  61.4 mm (2.417 in.)
  
  HINT:
  
  The vernier calipers must contact the chain rollers for the measurement.
  
  If the diameter is less than the minimum, replace the chain and sprocket.
  
  Fig 21: Checking Crankshaft Timing Sprocket Diameter With Chain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT IDLE SPROCKET ASSEMBLY
1. Wrap the chain around the sprocket.
2. Using vernier calipers, measure the sprocket diameter with the chain.
  Minimum sprocket diameter (with chain):
  
  61.4 mm (2.417 in.)
  
  HINT:
  
  The vernier calipers must contact the chain rollers for the measurement.
  
  If the diameter is less than the minimum, replace the chain and sprocket.
  
  Fig 22: Checking Idle Sprocket Diameter With Chain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT IDLE GEAR SHAFT OIL CLEARANCE
1. Using a micrometer, measure the idle gear shaft diameter.
  Idle gear shaft diameter:
  
  22.987 to 23.000 mm (0.9050 to 0.9055 in.)
  
  Fig 23: Checking Idle Gear Shaft Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a caliper gauge, measure the inside diameter of the idle gear.
  Idle gear inside diameter:
  
  23.020 to 23.030 mm (0.9063 to 0.9067 in.)
3. Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement.
  Standard oil clearance:
  
  0.020 to 0.043 mm (0.0008 to 0.0017 in.)
  
  Maximum oil clearance:
  
  0.093 mm (0.0037 in.)
  
  If the thrust oil clearance is greater than the maximum, replace the idle gear shaft and idle gear.
  
  Fig 24: Checking Inside diameter Of Idle Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY
1. Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly. If necessary, replace the chain tensioner assembly.
  
  Fig 25: Moving Stopper Plate Upward To Release Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
1. Check that the plunger moves smoothly.
2. Measure the worn depth of the chain tensioner.
  Maximum Depth:
  
  0.9 mm (0.035 in.)
  
  If the depth is greater than the maximum, replace the chain tensioner assembly.
  
  Fig 26: Measuring Worn depth Of Chain Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY
1. Check that the plunger moves smoothly.
2. Measure the worn depth of the chain tensioner.
  Maximum Depth:
  
  0.9 mm (0.035 in.)
  
  If the depth is greater than the maximum, replace the chain tensioner assembly.
  
  Fig 27: Measuring Worn Depth Of Chain Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CHAIN TENSIONER SLIPPER
1. Measure the worn depth of the chain tensioner slipper.
  Maximum Depth:
  
  1.0 mm (0.039 in.)
  
  If the depth is greater than the maximum, replace the chain tensioner slipper.
  
  Fig 28: Measuring Worn Depth Of Chain Tensioner Slipper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 CHAIN VIBRATION DAMPER
1. Measure the worn depth of the chain vibration damper.
  Maximum depth:
  
  1.0 mm (0.039 in.)
  
  If the depth is greater than the maximum, replace the chain vibration damper.
  
  Fig 29: Measuring Worn Depth Of Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 CHAIN VIBRATION DAMPER
1. Measure the worn depth of the chain vibration damper.
  Maximum depth:
  
  1.0 mm (0.039 in.)
  
  If the depth is greater than the maximum, replace the chain vibration damper.
  
  Fig 30: Measuring Worn Depth Of No 2 Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CYLINDER HEAD ASSEMBLY

Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder block and manifolds.

Standard warpage

STANDARD WARPAGE SPECIFICATION

Item	Warpage
Cylinder head lower	0.05 mm (0.0020 in.)
Intake	0.08 mm (0.0031 in.)
Exhaust	0.08 mm (0.0031 in.)

Maximum warpage

MAXIMUM WARPAGE SPECIFICATION

Item	Warpage
Cylinder head lower	0.10 mm (0.0039 in.)
Intake	0.10 mm (0.0039 in.)
Exhaust	0.10 mm (0.0039 in.)

If the warpage is greater than the maximum, replace the cylinder head assembly.

Fig 31: Measuring Warpage Of Contact Surface Of Cylinder Block And Manifolds

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a dye penetrant, check the intake ports, exhaust ports, and cylinder surface for cracks. If cracked, replace the cylinder head assembly.

Fig 32: Checking Intake Ports, Exhaust Ports And Cylinder Surface For Cracks
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT INTAKE VALVE
1. Using a micrometer, measure the diameter of the valve stem.
  Valve stem diameter:
  
  5.470 to 5.485 mm (0.2154 to 0.2159 in.)
  
  If the valve stem is not as specified, check the oil clearance.
  
  Fig 33: Checking Diameter Of Valve Stem
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using vernier calipers, measure the valve head margin thickness.
  Standard margin thickness:
  
  1.0 mm (0.0394 in.)
  
  Minimum margin thickness:
  
  0.5 mm (0.0197 in.)
  
  If the margin thickness is less than the minimum, replace the intake valve.
  
  Fig 34: Identifying Valve Head Margin Thickness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using vernier calipers, measure the valve's overall length.
  Standard overall length:
  
  105.85 mm (4.1673 in.)
  
  Minimum overall length:
  
  105.35 mm (4.1476 in.)
  
  If the overall length is less than the minimum, replace the intake valve.
  
  Fig 35: Identifying Valve Overall Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT EXHAUST VALVE
1. Using a micrometer, measure the diameter of the valve stem.
  Valve stem diameter:
  
  5.465 to 5.480 mm (0.2151 to 0.2157 in.)
  
  If the valve stem is not as specified, check the oil clearance.
  
  Fig 36: Checking Diameter Of Exhaust Valve Stem
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using vernier calipers, measure the valve head margin thickness.
  Standard margin thickness:
  
  1.0 mm (0.0394 in.)
  
  Minimum margin thickness:
  
  0.5 mm (0.0197 in.)
  
  If the margin thickness is less than the minimum, replace the exhaust valve.
  
  Fig 37: Identifying Valve Head Margin Thickness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using vernier calipers, measure the valve's overall length.
  Standard overall length:
  
  110.40 mm (4.3464 in.)
  
  Minimum overall length:
  
  109.90 mm (4.3268 in.)
  
  If the overall length is less than the minimum, replace the exhaust valve.
  
  Fig 38: Identifying Valve Overall Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INTAKE VALVE SEAT
1. Apply a light coat of Prussian blue to the valve face.
2. Lightly press the valve face against the valve seat.
3. Check the valve face and valve seat by using the following procedure.
  1. If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.
  2. If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat.
  3. Check that the valve seat contacts in the middle of the valve face with the width between 1.1 and 1.5 mm (0.043 and 0.059 in.).
    
    Fig 39: Applying Light Coat Of Prussian Blue (Or White Lead) To Valve Face
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT EXHAUST VALVE SEAT
1. Apply a light coat of Prussian blue to the valve face.
2. Lightly press the valve face against the valve seat.
3. Check the valve face and valve seat by using the following procedure.
  1. If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.
  2. If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat.
  3. Check that the valve seat contacts in the middle of the valve face with the width between 1.1 and 1.5 mm (0.043 and 0.059 in.).
    
    Fig 40: Applying Light Coat Of Prussian Blue (Or White Lead) To Valve Face
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPAIR INTAKE VALVE SEAT
NOTE:
- Repair the seat while checking the seating position.
- Keep the lip free of foreign matter.
1. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification.
  
  Fig 41: Resurfacing Valve Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using 30° and 60° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat.
  Width:
  
  1.1 to 1.5 mm (0.043 to 0.059 in.)
3. Handrub the valve and valve seat with an abrasive compound.
4. Check the valve seating position.
  
  Fig 42: Identifying Valve Seat Width
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPAIR EXHAUST VALVE SEAT
NOTE:
- Repair the seat while checking the seating position.
- Keep the lip free of foreign matter.
1. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification.
  
  Fig 43: Resurfacing Valve Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using 30° and 75° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat.
  Width:
  
  1.1 to 1.5 mm (0.043 to 0.059 in.)
3. Handrub the valve and valve seat with an abrasive compound.
4. Check the valve seating position.
  
  Fig 44: Correcting Valve Seat Using 30° And 75° Cutters
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT COMPRESSION SPRING
1. Using vernier calipers, measure the free length of the compression spring.
  Free length:
  
  45.46 mm (1.7898 in.)
  
  If the free length is not as specified, replace the spring.
  
  Fig 45: Checking Free Length Of Inner Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a steel square, measure the deviation of the inner compression spring.
  Maximum deviation:
  
  1.0 mm (0.039 in.)
  
  Maximum angle (reference):
  
  2°
  
  If the deviation is greater than the maximum, replace the spring.
  
  Fig 46: Measuring Deviation Of Inner Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT VALVE GUIDE BUSH OIL CLEARANCE

Using a caliper gauge, measure the inside diameter of the guide bush.
Bush inside diameter:

5.510 to 5.530 mm (0.2169 to 0.2177 in.)

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

Standard clearance

STANDARD CLEARANCE SPECIFICATION

Item	Clearance
Intake	0.025 to 0.060 mm (0.0010 to 0.0024 in.)
Exhaust	0.030 to 0.065 mm (0.0012 to 0.0026 in.)

Maximum oil clearance

MAXIMUM OIL CLEARANCE SPECIFICATION

Item	Clearance
Intake	0.08 mm (0.0032 in.)
Exhaust	0.10 mm (0.0039 in.)

Fig 47: Checking Inside Diameter Of Guide Bush

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

For intake side:

If the clearance is greater than the maximum, replace the intake valve and intake guide bush.

For exhaust side:

If the clearance is greater than the maximum, replace the exhaust valve and exhaust guide bush.

INSPECT CAMSHAFT THRUST CLEARANCE
1. Inspect the RH bank camshaft thrust clearance.
  1. Install the RH bank camshafts (See REASSEMBLY ).
  2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
    Standard thrust clearance:
    
    0.08 to 0.13 mm (0.0031 to 0.0051 in.)
    
    Maximum thrust clearance:
    
    0.15 mm (0.006 in.)
    
    If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.
    
    Fig 48: Checking Camshaft Thrust Clearance
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect the LH bank camshaft thrust clearance.
  1. Install the LH bank camshafts (See REASSEMBLY ).
  2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
    Standard thrust clearance:
    
    0.08 to 0.13 mm (0.0031 to 0.0051 in.)
    
    Maximum thrust clearance:
    
    0.15 mm (0.006 in.)
    
    If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

INSPECT CAMSHAFT OIL CLEARANCE

Clean the bearing caps, camshaft housing, and camshaft journals.
Place the camshafts on the camshaft housing.
Lay a strip of Plastigage across each of the camshaft journals.
Install the bearing caps (See REASSEMBLY ).
NOTE: do not turn the camshaft.
Remove the bearing caps (See DISASSEMBLY ).

Fig 49: Checking Camshaft Oil Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Measure the Plastigage at its widest point.

Standard oil clearance

STANDARD OIL CLEARANCE SPECIFICATION

Item	Oil Clearance
No. 1 journal	0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journals	0.025 to 0.062 mm (0.00098 to 0.0024 in.)

Maximum oil clearance

MAXIMUM OIL CLEARANCE SPECIFICATION

Item	Oil Clearance
No. 1 journal	0.10 mm (0.0039 in.)
Other journals	0.09 mm (0.0035 in.)

If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.

Clean the bearing caps, camshaft housing, and camshaft journals.
Place the camshafts on the camshaft housing.

Fig 50: Measuring Plastigage At Camshaft Widest Point
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Lay a strip of Plastigage across each of the camshaft journals.
Install the bearing caps (See REASSEMBLY ).
NOTE: do not turn the camshaft.
Remove the bearing caps (See DISASSEMBLY ).

Fig 51: Laying Strip Of Plastigage Across Each Of Camshaft Journals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Measure the Plastigage at Its widest point.

Standard oil clearance

STANDARD OIL CLEARANCE SPECIFICATION

Item	Oil Clearance
No. 1 journal	0.040 to 0.079 mm (0.0016 to 0.0031 in.)
Other journals	0.025 to 0.062 mm (0.00098 to 0.0024 in.)

Maximum oil clearance

MAXIMUM OIL CLEARANCE SPECIFICATION

Item	Oil Clearance
No. 1 journal	0.10 mm (0.0039 in.)
Other journals	0.09 mm (0.0035 in.)

If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.

Fig 52: Measuring Plastigage At Camshaft Widest Point

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CONNECTING ROD THRUST CLEARANCE
1. Install the connecting rod cap (See REASSEMBLY ).
2. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
  Standard thrust clearance:
  
  0.15 to 0.40 mm (0.0059 to 0.0157 in.)
  
  Maximum thrust clearance:
  
  0.50 mm (0.020 in.)
  
  If the thrust clearance is greater than the maximum, replace the connecting rod assemblies as necessary. If necessary, replace the crankshaft.

INSPECT CONNECTING ROD OIL CLEARANCE

Clean the crank pin and bearing.
Check the crank pin and bearing for pitting and scratches.

Fig 53: Checking Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Lay a strip of Plastigage on the crank pin.

Fig 54: Laying Strip Of Plastigage On Crank Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check that the front mark of the connecting rod cap is facing forward.
Install the connecting rod cap (See REASSEMBLY ).
NOTE: Do not turn the crankshaft.
Remove the 2 bolts and connecting rod cap (See DISASSEMBLY ).

Fig 55: Checking Front Mark Of Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Measure the Plastigage at its widest point.

Standard oil clearance:

0.045 to 0.067 mm (0.0018 to 0.0026 in.)

Maximum oil clearance:

0.070 mm (0.0028 in.)

If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.

HINT:

If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, 3, or 4 mark on its surface.

Connecting rod diameter

CONNECTING ROD DIAMETER SPECIFICATION

Mark	Diameter
1	56.000 to 56.006 mm (2.2047 to 2.2050 in.)
2	56.007 to 56.012 mm (2.2050 to 2.2052 in.)
3	56.013 to 56.018 mm (2.2052 to 2.2054 in.)
4	56.019 to 56.024 mm (2.2055 to 2.2057 in.)

Connecting rod bearing center wall thickness

CONNECTING ROD BEARING CENTER WALL THICKNESS SPECIFICATION

Mark	Thickness
1	1.481 to 1.484 mm (0.0583 to 0.0584 in.)
2	1.484 to 1.487 mm (0.0584 to 0.0585 in.)
3	1.487 to 1.490 mm (0.0585 to 0.0587 in.)
4	1.490 to 1.493 mm (0.0587 to 0.0588 in.)

Crankshaft pin diameter:

52.992 to 53.000 mm (2.0863 to 2.0866 in.)

NOTE: Completely remove the Plastigage after the measurement.

INSPECT CRANKSHAFT THRUST CLEARANCE
1. Install the main bearing cap (See REASSEMBLY ).
  
  Fig 56: Measuring Plastigage Widest Point
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
  Standard thrust clearance:
  
  0.04 to 0.24 mm (0.0016 to 0.0094 in.)
  
  Maximum thrust clearance:
  
  0.30 mm (0.0118 in.)
  
  If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.
  
  Thrust washer thickness:
  
  2.43 to 2.48 mm (0.0957 to 0.0976 in.)
  
  Fig 57: Measuring Crankshaft Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER BLOCK FOR WARPAGE
1. Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.
  Maximum warpage:
  
  0.07 mm (0.0028 in.)
  
  If the warpage is greater than the maximum, replace the cylinder block.
  
  Fig 58: Measuring Warpage Of Contact Surface Of Cylinder Head Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CYLINDER BORE
1. Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 6 cylinders. If necessary, replace the cylinder block.
  
  Fig 59: Checking Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
  Standard diameter:
  
  94.000 to 94.012 mm (3.7008 to 3.7013 in.)
  
  Maximum diameter:
  
  94.200 mm (3.7087 in.)
  
  If the average diameter of 4 positions is greater than the maximum, replace the cylinder block.
  
  Fig 60: Measuring Cylinder Bore Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PISTON SUB-ASSEMBLY WITH PIN
1. Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston end is as specified.
  Distance:
  
  9.8 mm (0.3858 in.)
  
  Standard diameter:
  
  93.960 to 93.980 mm (3.6992 to 3.7000 in.)
  
  Maximum diameter:
  
  93.830 mm (3.6941 in.)
  
  Fig 61: Checking Piston Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PISTON OIL CLEARANCE
1. Measure the cylinder bore diameter in the thrust directions.
2. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
  Standard oil clearance:
  
  0.020 to 0.052 mm (0.0008 to 0.0020 in.)
  
  Maximum oil clearance:
  
  0.060 mm (0.0024 in.)
  
  If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.

INSPECT RING GROOVE CLEARANCE

Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

Ring groove clearance

RING GROOVE CLEARANCE SPECIFICATION

Item	Clearance
No. 1	0.020 to 0.070 mm (0.0008 to 0.0028 in.)
No. 2	0.020 to 0.060 mm (0.0008 to 0.0024 in.)
Oil	0.070 to 0.150 mm (0.0028 to 0.0059 in.)

If the clearance is not as specified, replace the piston.

Fig 62: Measuring Cylinder Bore Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PISTON RING END GAP

Insert the piston ring into the cylinder bore.
Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block.

Fig 63: Inserting Piston Ring Into Cylinder Bore
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a feeler gauge, measure the end gap.

Standard end gap

STANDARD END GAP SPECIFICATION

Item	End Gap
No. 1	0.25 to 0.35 mm (0.0098 to 0.0138 in.)
No. 2	0.50 to 0.60 mm (0.0197 to 0.0236 in.)
Oil	0.10 to 0.40 mm (0.0039 to 0.0157 in.)

Maximum end gap

MAXIMUM END GAP SPECIFICATION

Item	End Gap
No. 1	0.50 mm (0.0197 in.)
No. 2	0.85 mm (0.0335 in.)
Oil	0.60 mm (0.0236 in.)

If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, rebore all the 6 cylinders or replace the cylinder block.

Fig 64: Checking End Gap

INSPECT PISTON PIN OIL CLEARANCE

Using a caliper gauge, measure the inside diameter of the piston pin hole.

Piston pin hole inside diameter

PISTON PIN HOLE INSIDE DIAMETER SPECIFICATION

Mark	Diameter
A	22.001 to 22.004 mm (0.8662 to 0.8663 in.)
B	22.004 to 22.007 mm (0.8663 to 0.8664 in.)
C	22.007 to 22.010 mm (0.8664 to 0.8665 in.)

Fig 65: Measuring Inside Diameter Of Piston Pin Hole

Using a micrometer, measure the piston pin diameter.

Piston pin diameter

PISTON PIN DIAMETER SPECIFICATION

Mark	Diameter
A	21.997 to 22.000 mm (0.8660 to 0.8661 in.)
B	22.000 to 22.003 mm (0.8661 to 0.8663 in.)
C	22.003 to 22.006 mm (0.8663 to 0.8664 in.)

Subtract the piston pin diameter measurement from the piston pin hole diameter measurement.
Standard oil clearance:

0.001 to 0.007 mm (0.00004 to 0.00028 in.)

Maximum oil clearance:

0.015 mm (0.0006 in.)

If the oil clearance is greater than the maximum, replace the piston and piston pin as a set.

Fig 66: Checking Piston Pin diameter
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a caliper gauge, measure the inside diameter of the connecting rod bushing.

Bushing inside diameter

BUSHING INSIDE DIAMETER SPECIFICATION

Mark	Diameter
A	22.005 to 22.008 mm (0.8663 to 0.8665 in.)
B	22.009 to 22.011 mm (0.8665 to 0.8666 in.)
C	22.012 to 22.014 mm (0.8666 to 0.8667 in.)

Fig 67: Checking Inside Diameter Of Connecting Rod Bushing

Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Standard oil clearance:

0.005 to 0.011 mm (0.0002 to 0.0004 in.)

Maximum oil clearance:

0.030 mm (0.0012 in.)

If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin as a set.

Fig 68: Identifying Front Mark Of Piston Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CONNECTING ROD
1. Using a rod aligner and feeler gauge, check the connecting rod alignment.
  1. Check for out-of-alignment.
    Maximum out-of-alignment:
    
    0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
    
    If the out-of-alignment is greater than the maximum, replace the connecting rod assembly.
    
    Fig 69: Checking Connecting Rod
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check for twist.
    Maximum twist:
    
    0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
    
    If the twist is greater than the maximum, replace the connecting rod assembly.
    
    Fig 70: Checking Connecting Rod For Twist
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CONNECTING ROD BOLT
1. Using vernier calipers, measure the tension portion diameter of the bolt.
  Standard diameter:
  
  7.2 to 7.3 mm (0.284 to 0.287 in.)
  
  Minimum diameter:
  
  7.0 mm (0.276 in.)
  
  If the diameter is less than the minimum, replace the bolt.
INSPECT CRANKSHAFT
1. Inspect for circle runout.
  1. Clean the crank journal.
  2. Place the crankshaft on V-blocks.
    
    Fig 71: Identifying Tension Portion Diameter Of Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Using a dial indicator, measure the circle runout at the center journal.
    Maximum circle runout:
    
    0.06 mm (0.0024 in.)
    
    If the circle runout is greater than the maximum, replace the crankshaft.
    
    Fig 72: Checking Circle Runout Center Journal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect the main journals.
  1. Using a micrometer, measure the diameter of each main journal.
    Standard journal diameter:
    
    60.988 to 61.000 mm (2.4011 to 2.4016 in.)
    
    If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.
  2. Check each main journal for taper and out-of-round as shown in the illustration.
    Maximum taper and out-of-round:
    
    0.02 mm (0.0008 in.)
    
    If the taper and out-of-round is greater than the maximum, replace the crankshaft.
    
    Fig 73: Checking Main Journal For Taper And Out-Of Round
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Inspect the crank pin.
  1. Using a micrometer, measure the diameter of each crank pin.
    Crankshaft pin diameter:
    
    52.992 to 53.000 mm (2.0863 to 2.0866 in.)
    
    If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.
  2. Check each crank pin for taper and out-of-round as shown in the illustration.
    Maximum taper and out-of-round:
    
    0.02 mm (0.0008 in.)
    
    If the taper and out-of-round is greater than the maximum, replace the crankshaft.
    
    Fig 74: Checking Crank Pin For Taper And Out-Of Round
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CRANKSHAFT OIL CLEARANCE

Check the crank journal and bearing for pitting and scratches.
Install the crankshaft bearing (See REASSEMBLY ).
Place the crankshaft on the cylinder block.
Lay a strip of Plastigage across each journal.
Examine the front marks and numbers and install the bearing caps on the cylinder block.
HINT:

A number is marked on each main bearing cap to indicate the installation position.
Install the main bearing cap (See REASSEMBLY ).
NOTE: Do not turn the crankshaft.
Remove the main bearing caps (See DISASSEMBLY ).

Fig 75: Laying Strip Of Plastigage Across Each Journal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Measure the Plastigage at its widest point.
Standard oil clearance:

0.026 to 0.047 mm (0.0010 to 0.0019 in.)

Maximum oil clearance:

0.050 mm (0.0020 in.)

If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.

NOTE: Completely remove the Plastigage after the measurement.

Fig 76: Measuring Plastigage At Widest Point
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If replacing a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

Journal bearings:

JOURNAL BEARINGS

Cylinder block + Crankshaft	0 - 5	6 - 11	12 - 17	18 - 23	24 - 28
Bearing to be used	"1"	"2"	"3"	"4"	"5"

HINT:

EXAMPLE: Cylinder block "11" + Crankshaft "06" Total number 17 (Use bearing "3")

Crankshaft main journal diameter

CRANKSHAFT MAIN JOURNAL DIAMETER SPECIFICATION

Mark	Diameter
"00"	60.999 to 61.000 mm (2.4015 to 2.4016 in.)
"01"	60.998 to 60.999 mm (2.4015 to 2.4015 in.)
"02"	60.997 to 60.998 mm (2.4015 to 2.4015 in.)
"03"	60.996 to 60.997 mm (2.4014 to 2.4015 in.)
"04"	60.995 to 60.996 mm (2.4014 to 2.4014 in.)
"05"	60.994 to 60.995 mm (2.4013 to 2.4014 in.)
"06"	60.993 to 60.994 mm (2.4013 to 2.4013 in.)
"07"	60.992 to 60.993 mm (2.4013 to 2.4013 in.)
"08"	60.991 to 60.992 mm (2.4012 to 2.4013 in.)
"09"	60.990 to 60.991 mm (2.4012 to 2.4012 in.)
"10"	60.989 to 60.990 mm (2.4011 to 2.4012 in.)
"11"	60.988 to 60.989 mm (2.4011 to 2.4011 in.)

Fig 77: Identifying Journal Bearing Diameter

Standard upper bearing center wall thickness (No. 1 and No. 4 journal)

STANDARD UPPER BEARING CENTER WALL THICKNESS (NO. 1 AND NO. 4 JOURNAL)

Mark	Thickness
"1"	2.500 to 2.503 mm (0.0984 to 0.0985 in.)
"2"	2.503 to 2.506 mm (0.0985 to 0.0987 in.)
"3"	2.506 to 2.509 mm (0.0987 to 0.0988 in.)
"4"	2.509 to 2.512 mm (0.0988 to 0.0989 in.)
"5"	2.512 to 2.515 mm (0.0989 to 0.0990 in.)

Standard lower bearing center wall thickness (No. 1 and No. 4 journal)

STANDARD LOWER BEARING CENTER WALL THICKNESS (NO. 1 AND NO. 4 JOURNAL)

Mark	Thickness
"1"	2.478 to 2.481 mm (0.0976 to 0.0977 in.)
"2"	2.481 to 2.484 mm (0.0977 to 0.0978 in.)
"3"	2.484 to 2.487 mm (0.0978 to 0.0979 in.)
"4"	2.487 to 2.490 mm (0.0979 to 0.0980 in.)
"5"	2.490 to 2.493 mm (0.0980 to 0.0981 in.)

Standard upper bearing center wall thickness (No. 2 and No. 3 journal)

STANDARD UPPER BEARING CENTER WALL THICKNESS (NO. 2 AND NO. 3 JOURNAL)

Mark	Thickness
"1"	2.478 to 2.481 mm (0.0976 to 0.0977 in.)
"2"	2.481 to 2.484 mm (0.0977 to 0.0978 in.)
"3"	2.484 to 2.487 mm (0.0978 to 0.0979 in.)
"4"	2.487 to 2.490 mm (0.0979 to 0.0980 in.)
"5"	2.490 to 2.493 mm (0.0980 to 0.0981 in.)

Standard lower bearing center wall thickness (No. 2 and No. 3 journal)

STANDARD LOWER BEARING CENTER WALL THICKNESS (NO. 2 AND NO. 3 JOURNAL)

Mark	Thickness
"1"	2.500 to 2.503 mm (0.0984 to 0.0985 in.)
"2"	2.503 to 2.506 mm (0.0985 to 0.0987 in.)
"3"	2.506 to 2.509 mm (0.0987 to 0.0988 in.)
"4"	2.509 to 2.512 mm (0.0988 to 0.0989 in.)
"5"	2.512 to 2.515 mm (0.0989 to 0.0990 in.)

INSPECT CRANKSHAFT BEARING CAP SET BOLT
1. Using vernier calipers, measure the minimum diameter of the compressed thread at the measuring point.
  Standard diameter:
  
  10.8 to 11.0 mm (0.4252 to 0.4331 in.)
  
  Minimum diameter:
  
  10.7 mm (0.4213 in.)
  
  Measuring Point:
  
  40 mm (1.57 in.)
  
  If the diameter is less than the minimum, replace the bolt.
  
  Fig 78: Identifying Crankshaft Bearing Cap Bolt Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002