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Engine Unit: Inspection

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  1. INSPECT VALVE LASH ADJUSTER ASSEMBLY 
    NOTE:
    • Keep the lash adjuster free from dirt and foreign objects.
    • Only use clean engine oil.
      Fig 1: Locating Oil Nozzles
      G04996761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Place the lash adjuster into a container full of engine oil.
    2. Insert 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 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 high-pressure air from the compression chamber, make sure that the tip of SST is actually pressing the checkball as shown in the illustration. If the checkball is not pressed, air will not bleed.
    5. After bleeding the air, remove SST. Then 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: Inserting SST's Tip Into Lash Adjuster's Plunger
      G04996762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT CAMSHAFTS 
    1. Inspect 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
        G04996763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a micrometer, measure the cam lobe height.

      Standard cam lobe height 

      CAM LOBE HEIGHT SPECIFICATION

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

      Maximum cam lobe height 

      CAM LOBE HEIGHT SPECIFICATION

      Item Specification
      Intake 44.166 mm (1.7388 in.)
      Exhaust 44.112 mm (1.7367 in.)
      Fig 4: Measuring Cam Lobe Height
      G04996764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a micrometer, measure the journal diameter.

      Standard journal diameter 

      JOURNAL DIAMETER

      Item Specification
      No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
      Other journal 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: Measuring Journal Diameter
      G04996765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 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.
      CAUTION: 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 fringe and the camshaft.
      Fig 6: Aligning Key Groove And Straight Pin
      G04996766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Tighten the fringe 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: Tightening Fringe Bolt With Camshaft Timing Gear
        G04996767Courtesy 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: Identifying Vinyl Tape Area
        G04974662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Apply approximately 200 kPa (2.0 kgf/cm2 , 28 psi) of air pressure to the two broken paths.
        CAUTION: Cover the paths with a shop rag or piece of cloth when applying pressure to keep oil from splashing.
        Fig 9: Applying Air Pressure To Broken Paths
        G04974663Courtesy 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: Checking Camshaft Timing Gear Revolves In Advance Direction
        G04974664Courtesy 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.
        CAUTION: 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 fringe bolt and camshaft timing gear.
      NOTE:
      • Be sure not to remove the other 3 bolts.
      • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.
  4. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Clamp the camshaft in a vise.
      NOTE: Be careful not to damage the camshaft in the vise.
      Fig 11: Identifying Fringe Bolt
      G04996771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      CAUTION: 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 fringe and the camshaft.
      Fig 12: Aligning Key Groove And Straight Pin
      G04996772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Tighten the fringe 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: Tightening Fringe Bolt With Camshaft Timing Exhaust Gear
        G04996773Courtesy 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: Identifying Vinyl Tape Area
        G04996774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Apply approximately 200 kPa (2.0 kgf/cm2 , 28 psi) of air pressure to the two broken paths (the advance side path and the retard side path).
        NOTE: Cover the paths with a shop rag or piece of cloth when applying pressure to keep oil from splashing.
        Fig 15: Applying Air Pressure To Broken Paths
        G04996775Courtesy 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: Turning Camshaft Timing Exhaust Gear
        G04996776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. When the camshaft timing exhaust gear comes 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 fringe bolt and camshaft timing exhaust gear.
      NOTE:
      • Be sure not to remove the other 3 bolts.
      • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.
        Fig 17: Identifying Fringe Bolt And Camshaft Timing Exhaust Gear
        G05405054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT CYLINDER HEAD SET 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.) 

      Fig 18: Measuring Cylinder Head Set Bolt Length
      G04974672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • If a visual check reveals no excessively thin areas, check the center of the bolt (see illustration) and find the area that has the lowest diameter.
      • If the diameter is less than the minimum, replace the cylinder head bolt.
  6. 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.) 

      If the elongation is greater than the maximum, replace the chain.

      NOTE: Perform the same measurement by pulling at random in 3 or more places to obtain an average.
      Fig 19: Measuring Length Of Links
      G04996779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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.) 

      If the elongation is greater than the maximum, replace the chain.

      NOTE: Perform the same measurement by pulling at random in 3 or more places to obtain an average.
      Fig 20: Measuring Length Of Links
      G04996779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSPECT CRANKSHAFT TIMING GEAR 
    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: Measuring Sprocket Diameter With Chain
        G04962338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. 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: Measuring Sprocket Diameter With Chain
        G04962339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSPECT IDLE GEAR SHAFT OIL CLEARANCE 
    1. Using a micrometer, measure the idle gear shaft diameter.

      Idle gear shaft diameter: 30.000 to 30.013 mm (1.1811 to 1.1816 in.) 

      Fig 23: Measuring Idle Gear Shaft Diameter
      G04962340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a caliper gauge, measure the inside diameter of the idle gear.

      Idle gear inside diameter: 30.020 to 30.033 mm (1.1819 to 1.1824 in.) 

    3. Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement.

      Standard oil clearance: 0.007 to 0.033 mm (0.0003 to 0.0013 in.) 

      Maximum oil clearance: 0.083 mm (0.0033 in.) 

      If the thrust oil clearance is greater than the maximum, replace the idle gear shaft and idle gear.

      Fig 24: Measuring Inside Diameter Of Idle Gear
      G04962341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. 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 No. 1.
      Fig 25: Inspecting No. 1 Chain Tensioner Assembly
      G04996785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY 
    1. Check that the plunger moves smoothly.
    2. Measure the worn depth of the chain tensioner slipper.

      Maximum depth: 0.9 mm (0.035 in.) 

      If the depth is greater than the maximum, replace the chain tensioner No. 2.

      Fig 26: Measuring Worn Depth Of Chain Tensioner Slipper
      G04996786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY 
    1. Check that the plunger moves smoothly.
    2. Measure the worn depth of the chain tensioner slipper.

      Maximum depth: 0.9 mm (0.035 in.) 

      If the depth is greater than the maximum, replace the chain tensioner No. 3.

      Fig 27: Measuring Worn Depth Of Chain Tensioner Slipper
      G04996787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. 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
      G04996788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSPECT NO. 1 CHAIN VIBRATION DAMPER 
    1. Measure the worn depth of the chain vibration damper No. 1.

      Maximum depth: 1.0 mm (0.039 in.) 

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

      Fig 29: Measuring Worn Depth Of Chain Vibration Damper No. 1
      G04996789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSPECT NO. 2 CHAIN VIBRATION DAMPER 
    1. Measure the worn depth of the chain vibration damper No. 2.

      Maximum depth: 1.0 mm (0.039 in.) 

      If the depth is greater than the maximum, replace the chain vibration damper No. 2.

      Fig 30: Measuring Worn Depth Of Chain Vibration Damper No. 2
      G04996790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSPECT CYLINDER HEAD SUB-ASSEMBLY 
    1. Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder block and manifolds.

      Standard warpage 

      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: 0.10 mm (0.0039 in.) 

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

      Fig 31: Measuring Warpage Of Contact Surface Of Cylinder Block And Manifolds
      G04974685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a dye penetrate, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head.
      Fig 32: Checking Intake Ports, Exhaust Ports And Cylinder Surface For Cracks
      G04962353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. 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.) 

      Fig 33: Measuring Diameter Of Valve Stem
      G04996793Courtesy 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: Measuring Valve Head Margin Thickness
      G04996794Courtesy 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: Measuring Valve's Overall Length
      G04996795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. 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.) 

      Fig 36: Measuring Diameter Of Valve Stem
      G04996796Courtesy 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: Measuring Valve Head Margin Thickness
      G04996797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using vernier calipers, measure the valve's overall length.

      Standard overall length: 111.40 mm (4.3858 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: Measuring Valve's Overall Length
      G04996798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSPECT INTAKE VALVE SEATS 
    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: Inspecting Intake Valve Seats
        G04996799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSPECT EXHAUST VALVE SEATS 
    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 1.2 and 1.6 mm (0.047 and 0.063 in.).
        Fig 40: Inspecting Exhaust Valve Seats
        G04996799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REPAIR INTAKE VALVE SEATS 
    NOTE: Keep the lip free from foreign matter.
    1. If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.
      Fig 41: Identifying Valve Face Angle
      G04996801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.
    3. Handrub the valve and valve seat with an abrasive compound.
    4. Check the valve seating position.
  23. REPAIR EXHAUST VALVE SEATS 
    NOTE: Keep the lip free from foreign matter.
    Fig 42: Identifying Valve Seating Position Angle
    G04996802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.
      Fig 43: Identifying Valve Face Angle
      G04996801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. If the seating is too low on the valve face, use 45° and 75° cutters to correct the seat.
    3. Handrub the valve and valve seat with an abrasive compound.
    4. Check the valve seating position.
      Fig 44: Identifying Valve Seating Position Angle
      G04996804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSPECT INNER COMPRESSION SPRING 
    1. Using vernier calipers, measure the free length of the inner compression spring.

      Free length: 45.91 mm (1.8075 in.) 

      If the free length is not as specified, replace the spring.

      Fig 45: Measuring Free Length Of Inner Compression Spring
      G04996805Courtesy 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
      G04996806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSPECT VALVE GUIDE BUSH OIL CLEARANCE 
    1. 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.) 

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

      Standard clearance 

      Fig 47: Measuring Inside Diameter Of Guide Bush
      G05405084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      GUIDE BUSH SPECIFICATION

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

      Maximum oil clearance 

      OIL CLEARANCE CHART

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

      HINT:

      • If the clearance is greater than the maximum, replace the intake valve and intake guide bush.
      • If the clearance is greater than the maximum, replace the exhaust valve and exhaust guide bush.
  26. INSPECT 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: Measuring Thrust Clearance While Moving Camshaft Back And Forth
      G04996808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the LH bank camshafts (See REASSEMBLY  ).
    4. 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.

  27. INSPECT CAMSHAFT OIL CLEARANCE 
    1. Clean the bearing caps, camshaft housing and camshaft journals.
    2. Place the camshafts on the camshaft housing.
    3. Lay a strip of Plastigage across each of the camshaft journals.
    4. Install the bearing caps (See REASSEMBLY  ).
      NOTE: Do not turn the camshaft.
    5. Remove the bearing caps (See DISASSEMBLY  ).
      Fig 49: Identifying Plastigage
      G04996809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Measure the Plastigage at its widest point.

      Standard oil clearance 

      OIL CLEARANCE CHART

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

      Maximum oil clearance 

      OIL CLEARANCE CHART

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

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

    7. Clean the bearing caps, camshaft housing and camshaft journals.
    8. Place the camshafts on the camshaft housing.
      Fig 50: Measuring Plastigage At Widest Point
      G04996810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Lay a strip of Plastigage across each of the camshaft journals.
    10. Install the bearing caps (See REASSEMBLY  ).
      NOTE: Do not turn the camshaft.
    11. Remove the bearing caps (See DISASSEMBLY  ).
      Fig 51: Identifying Plastigage
      G04996811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Measure the Plastigage at its widest point.

      Standard oil clearance 

      OIL CLEARANCE CHART

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

      Maximum oil clearance 

      OIL CLEARANCE CHART

      Item Oil Clearance
      No. 1 journal 0.10 mm (0.0039 in.)
      Other journal 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 Widest Point
      G04996812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSPECT CONNECTING ROD THRUST CLEARANCE 
    1. 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. If necessary, replace the crankshaft.

      Fig 53: Measuring Thrust Clearance While Moving Connecting Rod Back And Forth
      G04996813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSPECT CONNECTING ROD OIL CLEARANCE 
    1. Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly (Procedure "A").

      HINT:

      The matchmarks on the connecting rods and caps are provided to ensure correct reassembly.

    2. Using SST, remove the 2 connecting rod cap bolts (Procedure "B").
      Fig 54: Removing Connecting Rod Cap Bolts
      G04974639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using the 2 removed connecting rod caps bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left (Procedure "C").

      HINT:

      Keep the lower bearing inserted to the connecting rod cap.

    4. Clean the crank pin and bearing (Procedure "D").
    5. Check the crank pin and bearing for pitting and scratches (Procedure "E").
      Fig 55: Removing Connecting Rod Caps Bolts
      G04974640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Lay a strip of Plastigage on the crank pin (Procedure "F").
      Fig 56: Identifying Plastigage On Crank Pin
      G04974708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Check that the front mark of the connecting rod cap is facing forward (Procedure "G").
      Fig 57: Identifying Front Mark Of Connecting Rod Cap
      G04974709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using SST, install the connecting rod cap (Procedure "H").
      NOTE: Do not turn the crankshaft.
    9. Remove the 2 bolts and connecting rod cap (see  bprocedure "B" and  c"C" above).
      Fig 58: Installing Connecting Rod Cap Bolts
      G04996818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. 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, replace 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 mark 1, 2, 3 or 4 on its surface.

      Reference: 

      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.)
      Fig 59: Measuring Plastigage At Widest Point
      G04996819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard bearing center wall thickness 

      BEARING CENTER WALL THICKNESS SPECIFICATION

      Mark Diameter
      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.) 

    11. Completely remove the Plastigage.
  30. INSPECT CRANKSHAFT THRUST CLEARANCE 
    1. 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 60: Measuring Crankshaft Thrust Clearance
      G04974711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. 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 61: Measuring Warpage Of Contact Surface Of Cylinder Head Gasket
      G04974712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 6 cylinders. If necessary, replace the cylinder block.
      Fig 62: Checking Cylinder For Vertical Scratches
      G04974713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSPECT CYLINDER BORE 
    1. 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 diameter is greater than the maximum, replace the cylinder block.

      Fig 63: Measuring Cylinder Bore Diameter At Positions A And B
      G04996823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. 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 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 64: Measuring Piston Diameter At Right Angles To Piston Center Line
      G04996824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSPECT PISTON OIL CLEARANCE 
    1. Measure the cylinder bore diameter in the thrust direction.
    2. Subtract the piston diameter measurement from the cylinder bore diameter measurement.

      Standard oil clearance: 0.02 to 0.052 mm (0.0008 to 0.0020 in.) 

      Maximum oil clearance: 0.06 mm (0.0024 in.) 

      If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.

  35. INSPECT RING GROOVE CLEARANCE 
    1. 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 00024 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 65: Measuring Clearance Between Piston Ring And Wall Of Ring Groove
      G04974716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSPECT PISTON RING END GAP 
    1. Insert the piston ring into the cylinder bore.
    2. 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 66: Pushing Piston Ring
      G04996826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a feeler gauge, measure the end gap.

      Standard end gap 

      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 

      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.)
      Fig 67: Measuring End Gap
      G04996827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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, replace the cylinder block.

  37. INSPECT PISTON PIN OIL CLEARANCE 
    1. 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 68: Measuring Inside Diameter Of Piston Pin Hole
      G04974719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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.)
      Fig 69: Measuring Piston Pin Diameter
      G04996829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. 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 0.0003 in.) 

      Maximum oil clearance: 0.015 mm (0.0006 in.) 

      HINT:

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

    4. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
      Fig 70: Measuring Inside Diameter Of Connecting Rod Bushing
      G04996830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.)
    5. 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: 0.03 mm (0.0012 in.) 

      HINT:

      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 71: Identifying Piston Pin Hole Inside Diameter Mark
      G04974722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. 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 72: Checking Connecting Rod Alignment
        G04996832Courtesy 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 73: Checking Connecting Rod Twist
        G04996833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE CONNECTING ROD SMALL END BUSH 
    1. Using SST and a press, press out the bush.

      SST 09222-30010 

      Fig 74: Pressing Out Bush
      G05405111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSPECT CONNECTING ROD BOLT 
    1. Using vernier calipers, measure the tension portion diameter of the bolt.

      Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.) 

      Minimum diameter: 7.0 mm (0.276 in.) 

      If the diameter is less than the minimum, replace the bolt.

      Fig 75: Measuring Tension Portion Diameter Of Bolt
      G04996835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSPECT CRANKSHAFT 
    1. Inspect for circle runout.
      1. Place the crankshaft on the V-blocks.
      2. 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 76: Measuring Circle Runout At Center Journal
        G04962399Courtesy 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 61.00 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 77: Measuring Diameter Of Main Journal
        G04962400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Inspect the crank pin.
      1. Using a micrometer, measure the diameter of each crank 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 78: Measuring Diameter Of Crank Pin
        G04962401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSPECT CRANKSHAFT OIL CLEARANCE 
    NOTE: Main bearings come in widths of 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.
    1. Clean the main journal and the both surfaces of the bearing.
      Fig 79: Identifying Main Journal Bearing Dimension
      G04996839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the upper bearing.
      1. Install the upper bearing to the cylinder block as shown in the illustration.
        NOTE: Do not apply engine oil to the bearing and its contact surface.
        Fig 80: Installing Upper Bearing
        G04996840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the lower bearing.
      1. Install the lower bearing to the bearing cap.
      2. Using vernier calipers, measure the distance between the bearing cap's edge and the lower bearing's edge.

        Dimension (A - B): 0.7 mm (0.0276 in.) or less 

        NOTE: Do not apply engine oil to the bearing's contact area and underside.
    4. Place the crankshaft on the cylinder block.
      Fig 81: Installing Lower Bearing To Bearing Cap
      G04974745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Lay a strip of Plastigage across each journal.
    6. 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.

    7. Apply a light coat of engine oil to the threads and under the head of bearing cap bolts.
    8. Temporarily install the 8 main bearing cap bolts to the inside positions.
      Fig 82: Identifying Plastigage
      G04996842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Insert the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.

      Bolt length: 100 to 102 mm (3.94 to 4.02 in.) 

      Fig 83: Checking Clearance Between Main Bearing Cap And Cylinder Block
      G04996843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using a plastic hammer, lightly tap the bearing cap to ensure a proper fit.
    11. Apply a light coat of engine oil to the threads and under the head of the 8 main bearing cap bolts.
      Fig 84: Tapping Bearing Cap
      G04974749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Install the 8 main bearing cap bolts to the outside positions.

      Bolt length: 105.5 to 107.5 mm (4.15 to 4.23 in.) 

      Fig 85: Identifying Bolt Length
      G04996845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Install and uniformly tighten the 16 main bearing cap bolts in several steps and in the sequence shown in the illustration.

      Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) 

      Fig 86: Tightening Main Bearing Cap Bolts
      G04996846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Mark the front side of the bearing cap bolts with paint.
    15. Tighten the bearing cap bolts another 90° in the sequence shown.
    16. Check that the painted mark is now at a 90° angle to the front.
      NOTE: Do not turn the crankshaft.
      Fig 87: Identifying Paint Mark On Bearing Cap Bolts
      G04996847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    17. Install and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration.

      Torque: 52 N*m (525 kgf*cm, 38 ft.*lbf) 

      HINT:

      • Bolt (A) length: 45 mm (1.77 in.)
      • Except bolt (A) length: 30 mm (1.18 in.)
    18. Remove the main bearing caps.
      Fig 88: Identifying Bearing Cap Bolts Tightening Sequence
      G04996848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    19. Measure the Plastigage at its widest point.

      Standard oil clearance: 0.026 to 0.047 mm (0.0010 to 0.0019 in.) 

      Maximum 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.
      Fig 89: Measuring Plastigage At Widest Point
      G04974730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    20. 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 SPECIFICATION

      Cylinder block (A) + Crankshaft 0-5 6-11 12-17 18-23 24-28
      Use Bearing "1" "2" "3" "4" "5"

      HINT:

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

      Fig 90: Identifying Number Mark On Crankshaft Bearing
      G04996850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.)
      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" 60.93 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 (2.4.011 to 2.4011 in.)

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

      UPPER BEARING CENTER WALL THICKNESS SPECIFICATION

      Mark Diameter
      "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 journals) 

      LOWER BEARING CENTER WALL THICKNESS SPECIFICATION

      Mark Diameter
      "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 thickness (No. 2 and No. 3 journals) 

      UPPER BEARING CENTER THICKNESS SPECIFICATION

      Mark Diameter
      "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 thickness (No. 2 and No. 3 journals) 

      LOWER BEARING CENTER THICKNESS SPECIFICATION

      Mark Diameter
      "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.)
  43. INSPECT CRANKSHAFT BEARING CAP SET BOLT 
    1. Using vernier calipers, measure the minimum diameter of the compressed thread at the measuring point.

      Standard diameter: 10.5 to 11.0 mm (0.4134 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 91: Measuring Minimum Diameter Of Compressed Thread At Measuring Point
      G04974732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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