Engine Unit: Inspection: Inspection

INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Turn the roller by hand to check that it turns smoothly.
  
  Fig 1: Turning Roller By Hand For Checking Smoothly Turns
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.

INSPECT VALVE LASH ADJUSTER ASSEMBLY

NOTE:

Keep the valve lash adjuster free from dirt and foreign matter.
Only use clean engine oil.

Place the lash adjuster into a container full of new engine oil.

Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

Fig 2: Identifying SST Components

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Plunger
*2	Check Ball
*3	Low Pressure Chamber
*4	High Pressure Chamber
*a	CORRECT
*b	INCORRECT
*c	Taper Part

SST: 09276-75010

Squeeze SST and the valve lash adjuster together to move the plunger up and down 5 to 6 times.
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 check ball as shown in the illustration. If the check ball is not pressed, air bleeding is not possible.
After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers.
OK

Plunger can be pressed 3 times.

If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster with a new one.

INSPECT CHAIN SUB-ASSEMBLY
1. Pull the chain with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.
  
  Fig 3: Inspecting Chain Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Measurement Length
2. Using a vernier caliper, measure the length of 15 links.
  Maximum chain elongation
  
  115.2 mm (4.54 in.)
  
  NOTE:
  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.
INSPECT NO. 2 CHAIN SUB-ASSEMBLY
1. Pull the chain with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.
  
  Fig 4: Inspecting Chain Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Measurement Length
2. Using a vernier caliper, measure the length of 15 links.
  Maximum chain elongation
  
  102.1 mm (4.02 in.)
  
  NOTE:
  Perform the measurement at 3 random places. Use the average of the measurements.
  
  If the average elongation is more than the maximum, replace the No. 2 chain sub-assembly.
INSPECT OIL PUMP DRIVE GEAR
1. Place the chain around the oil pump drive gear.
  
  Fig 5: Measuring Timing Gear Diameter With Chain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a vernier caliper, measure the diameter of the oil pump drive gear and chain.
  Minimum gear diameter (with chain)
  
  48.2 mm (1.90 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 and oil pump drive gear.
INSPECT OIL PUMP DRIVE SHAFT GEAR
1. Place the chain around the oil pump drive shaft gear.
  
  Fig 6: Inspecting Oil Pump Drive Shaft Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a vernier caliper, measure the diameter of the oil pump drive shaft gear and chain.
  Minimum gear diameter (with chain)
  
  48.2 mm (1.90 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 and oil pump drive shaft gear.
INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
1. Place the chain around the camshaft timing gear assembly.
  
  Fig 7: Inspecting Camshaft Timing Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a vernier caliper, measure the diameter of the camshaft timing gear assembly and chain.
  Minimum gear diameter (with chain)
  
  96.8 mm (3.81 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 and camshaft timing gear assembly.
INSPECT CAMSHAFT TIMING SPROCKET
1. Place the chain around the camshaft timing sprocket.
  
  Fig 8: Inspecting Camshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a vernier caliper, measure the diameter of the camshaft timing sprocket and chain.
  Minimum gear diameter (with chain)
  
  96.8 mm (3.81 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 and camshaft timing sprocket.
INSPECT CRANKSHAFT TIMING GEAR
1. Place the chain around the crankshaft timing gear.
  
  Fig 9: Measuring Timing Gear Diameter With Chain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a vernier caliper, measure the diameter of the crankshaft timing gear and chain.
  Minimum gear diameter (with chain)
  
  51.1 mm (2.01 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 and crankshaft timing gear.
INSPECT CHAIN TENSIONER SLIPPER
1. Using a vernier caliper, measure the chain tensioner slipper wear.
  
  Fig 10: Identifying Tensioner Slipper Wear Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum wear
  
  1.0 mm (0.0394 in.)
  
  If the wear is more than the maximum, replace the chain tensioner slipper.
INSPECT NO. 1 CHAIN VIBRATION DAMPER
1. Using a vernier caliper, measure the No. 1 chain vibration damper wear.
  
  Fig 11: Identifying Vibration Damper Wear Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum wear
  
  1.0 mm (0.0394 in.)
  
  If the wear is more than the maximum, replace the No. 1 chain vibration damper.
INSPECT NO. 2 CHAIN VIBRATION DAMPER
1. Using a vernier caliper, measure the No. 2 chain vibration damper wear.
  
  Fig 12: Identifying Vibration Damper Wear Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum wear
  
  1.0 mm (0.0394 in.)
  
  If the wear is more than the maximum, replace the No. 2 chain vibration damper.
INSPECT CHAIN TENSIONER PLATE
1. Using a vernier caliper, measure the chain tensioner plate wear.
  
  Fig 13: Identifying Vibration Damper Wear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum wear
  
  1.0 mm (0.0394 in.)
  
  If the wear is more than the maximum, replace the chain tensioner plate.

INSPECT NO. 1 CHAIN TENSIONER

Check that the plunger moves smoothly when the cam is raised with your finger.

Fig 14: Inspecting No. 1 Chain Tensioner

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*a	Lock
*b	Move
*c	Raise

Release the cam, then check that the plunger is locked in place by the cam and does not move when pushing with your finger.
If necessary, replace the No. 1 chain tensioner.

INSPECT CAMSHAFT

Inspect the camshaft for runout.

Fig 15: Inspecting Camshaft For Runout
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 (0.00157 in.)
  
  If the circle runout is more than the maximum, replace the camshaft.
Inspect the cam lobes.

Fig 16: Inspecting Cam Lobes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a micrometer, measure the cam lobe height.
  Standard cam lobe height
  
  41.779 to 41.879 mm (1.6448 to 1.6488 in.)
  
  Minimum cam lobe height
  
  41.629 mm (1.6389 in.)
  
  If the cam lobe height is less than the minimum, replace the camshaft.

Inspect the camshaft journals.

Fig 17: Inspecting Camshaft Journals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the journal diameter.

Standard Journal Diameter

Journal Position	Specified Condition
No. 1	34.449 to 34.465 mm (1.3563 to 1.3569 in.)
Other	22.949 to 22.965 mm (0.90350 to 0.90413 in.)

If the journal diameter is not as specified, check the oil clearance See step 5.

INSPECT NO. 2 CAMSHAFT

Inspect the No. 2 camshaft for runout.

Fig 18: Inspecting Camshaft For Runout
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Place the No. 2 camshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
  Maximum circle runout
  
  0.04 mm (0.00157 in.)
  
  If the circle runout is more than the maximum, replace the No. 2 camshaft.
Inspect the cam lobes.

Fig 19: Inspecting Cam Lobes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a micrometer, measure the cam lobe height.
  Standard cam lobe height
  
  43.346 to 43.446 mm (1.7065 to 1.7105 in.)
  
  Minimum cam lobe height
  
  43.196 mm (1.7006 in.)
  
  If the cam lobe height is less than the minimum, replace the No. 2 camshaft.

Inspect the camshaft journals.

Fig 20: Inspecting Camshaft Journals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the journal diameter.

Standard Journal Diameter

Journal Position	Specified Condition
No. 1	34.449 to 34.465 mm (1.3563 to 1.3569 in.)
Other	22.949 to 22.965 mm (0.90350 to 0.90413 in.)

If the journal diameter is not as specified, check the oil clearance See step 5.

INSPECT CYLINDER HEAD SET BOLT

Using a vernier caliper, measure the length of the cylinder head set bolt from the seat to the end.

Fig 21: Inspecting Cylinder Head Set Bolt

TEXT IN ILLUSTRATION

*a	Measurement Length
*b	Measurement Area
*c	Distance

Standard length

146.8 to 148.2 mm (5.78 to 5.83 in.)

Maximum length

149.2 mm (5.87 in.)

If the length is more than the maximum, replace the cylinder head set bolt.

Using a vernier caliper, measure the diameter of the elongated thread at the measurement point.
Measurement point

115 mm (4.53 in.)

Standard diameter

9.77 to 9.96 mm (0.385 to 0.392 in.)

Minimum diameter

9.4 mm (0.370 in.)

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

HINT:

If a visual check reveals no excessively thin areas, check the center of the bolt (refer to illustration) and find the area that has the smallest diameter.

INSPECT EXHAUST MANIFOLD
1. Using a precision straightedge and feeler gauge, measure the warpage on the surface that contacts the cylinder head.
  
  Fig 22: Measuring Warpage On Contact Surface Of Cylinder Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum warpage
  
  0.7 mm (0.0276 in.)
  
  If the warpage is more than the maximum, replace the exhaust manifold.