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: View Of Turning Roller By Hand For Checking Smoothly Turns
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  If the roller does not turn smoothly, replace the valve rocker arm sub-assembly.
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.
  
  Fig 2: Checking Movement Of Plunger Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - 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 high-pressure air from the compression 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 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.

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.
  
  Fig 3: View Of Measuring Circle Runout At Center Journal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.

Using a micrometer, measure the cam lobe height.

Fig 4: Measuring Cam Lobe Height

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard cam lobe height

Item	Specification
Intake camshaft	43.940 to 44.040 mm (1.7299 to 1.7339 in.)
Exhaust camshaft	44.090 to 44.190 mm (1.7358 to 1.7398 in.)

Maximum cam lobe height

Item	Specification
Intake camshaft	43.790 mm (1.7240 in.)
Exhaust camshaft	43.940 mm (1.7299 in.)

Using a micrometer, measure the journal diameter.

Fig 5: View Of Measuring Journal Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard 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.

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.
  
  Fig 6: Identifying Camshaft Timing Gear Assembly Components, Key Groove And Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
5. Tighten the flange bolt with the camshaft timing gear fixed.
  
  Fig 7: Tightening Flange Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
7. Release the lock pin.
  
  Fig 8: Covering Oil Paths Of Cam Journal With Vinyl Tape
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
  3. Apply approximately 200 kPa (2.0 kgf/cm² , 28 psi) of air pressure to the two broken paths.
    
    Fig 9: Applying Air Pressure To Two Broken Paths
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    WARNING:
    Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.
  4. Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path.
    
    Fig 10: Checking Camshaft Timing Gear Revolves In Advance Direction
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    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.
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.
  
  Fig 11: Identifying Straight Pin And Flange Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not remove the other 3 bolts.
  - If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.
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.
  
  Fig 12: Identifying Camshaft Timing Gear Assembly Components, Key Groove And Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
5. Tighten the flange bolt with the camshaft timing exhaust gear fixed.
  
  Fig 13: Tightening Flange Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
7. Release the lock pin.
  
  Fig 14: Covering Oil Paths Of Cam Journal With Vinyl Tape
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
  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).
    
    Fig 15: Applying Air Pressure To Two Broken Paths
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    WARNING:
    Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.
  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.
    
    Fig 16: Checking Camshaft Timing Exhaust Gear Turns In Retard Direction
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    HINT:
    
    The lock pin is released and the camshaft timing exhaust gear turns in the retard direction.
  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.
  
  Fig 17: Identifying Straight Pin And Flange Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be sure not to remove the other 4 bolts.
  - If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.
INSPECT CYLINDER HEAD SET BOLT
1. Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point.
  
  Fig 18: Identifying Cylinder Head Set Bolt Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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
  
  100 mm (3.94 in.)
  
  HINT:
  
  If a visual check reveals no excessively thin areas, 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.
INSPECT CHAIN SUB-ASSEMBLY
1. Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.
  
  Fig 19: Identifying Length Of Links
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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. Inspect using the average of the measurements.
  
  If the elongation is greater than the maximum, replace the chain.
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.
  
  Fig 20: Identifying Length Of Links
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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. Inspect using the average of the measurements.
  
  If the elongation is greater than the maximum, replace the chain.
INSPECT CRANKSHAFT TIMING SPROCKET
1. Wrap the chain around the sprocket.
2. Using vernier calipers, measure the sprocket diameter with the chain.
  
  Fig 21: Measuring Sprocket Diameter With Chain Sub-Assembly Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSPECT IDLE SPROCKET ASSEMBLY
1. Wrap the chain around the sprocket.
2. Using vernier calipers, measure the sprocket diameter with the chain.
  
  Fig 22: Measuring The Sprocket Diameter With The Chain Using A Vernier Caliper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSPECT IDLE GEAR SHAFT OIL CLEARANCE
1. Using a micrometer, measure the idle gear shaft diameter.
  
  Fig 23: Measuring Idle Gear Shaft Diameter Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Idle gear shaft diameter
  
  22.987 to 23.000 mm (0.9050 to 0.9055 in.)
2. Using a caliper gauge, measure the inside diameter of the idle gear.
  
  Fig 24: Measuring Inside Diameter Of Idle Sprocket Assembly Using A Caliper Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
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.
  
  Fig 25: Checking No. 1 Chain Tensioner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If necessary, replace the chain tensioner assembly.
INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
1. Check that the plunger moves smoothly.
  
  Fig 26: Checking No. 2 Chain Tensioner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY
1. Check that the plunger moves smoothly.
  
  Fig 27: Checking No. 3 Chain Tensioner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
INSPECT CHAIN TENSIONER SLIPPER
1. Measure the worn depth of the chain tensioner slipper.
  
  Fig 28: Identifying Worn Depth Of Chain Tensioner Slipper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum depth
  
  1.0 mm (0.039 in.)
  
  If the depth is greater than the maximum, replace the chain tensioner slipper.
INSPECT NO. 1 CHAIN VIBRATION DAMPER
1. Measure the worn depth of the chain vibration damper.
  
  Fig 29: Measuring Worn Depth Of Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum depth
  
  1.0 mm (0.039 in.)
  
  If the depth is greater than the maximum, replace the chain vibration damper.
INSPECT NO. 2 CHAIN VIBRATION DAMPER
1. Measure the worn depth of the chain vibration damper.
  
  Fig 30: Identifying Worn Depth Of No. 2 Chain Vibration Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum depth
  
  1.0 mm (0.039 in.)
  
  If the depth is greater than the maximum, replace the chain vibration damper.

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.

Fig 31: Measuring Warpage Of Contact Surface Of Cylinder Block & Manifolds Using Straight Edge & Feeler Gauge

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard warpage

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

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.

Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks.

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

If cracked, replace the cylinder head assembly.

INSPECT INTAKE VALVE
1. Using a micrometer, measure the diameter of the valve stem.
  
  Fig 33: View Of Measuring Diameter Of Valve Stem
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
2. Using vernier calipers, measure the valve head margin thickness.
  
  Fig 34: Identifying Valve Head Margin Thickness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard margin thickness
  
  1.0 mm (0.03937 in.)
  
  Minimum margin thickness
  
  0.5 mm (0.0197 in.)
  
  If the margin thickness is less than the minimum, replace the intake valve.
3. Using vernier calipers, measure the valve's overall length.
  
  Fig 35: Measuring Intake Valve's Overall Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard overall length
  
  106.15 mm (4.1791 in.)
  
  Minimum overall length
  
  105.65 mm (4.1594 in.)
  
  If the overall length is less than the minimum, replace the intake valve.
INSPECT EXHAUST VALVE
1. Using a micrometer, measure the diameter of the valve stem.
  
  Fig 36: Measuring Diameter Of Exhaust Valve Stem Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
2. Using vernier calipers, measure the valve head margin thickness.
  
  Fig 37: Measuring Valve Head Margin Thickness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard margin thickness
  
  0.81 mm (0.0319 in.)
  
  Minimum margin thickness
  
  0.31 mm (0.0122 in.)
  
  If the margin thickness is less than the minimum, replace the exhaust valve.
3. Using vernier calipers, measure the valve's overall length.
  
  Fig 38: Measuring Exhaust Valve Overall Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard overall length
  
  111.70 mm (4.3976 in.)
  
  Minimum overall length
  
  111.20 mm (4.3779 in.)
  
  If the overall length is less than the minimum, replace the exhaust valve.
INSPECT INTAKE VALVE SEAT
1. Apply a light coat of Prussian blue (or white lead) 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.
  
  Fig 39: Identifying Exhaust Valve Seat Width
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 1.0 and 1.4 mm (0.039 and 0.055 in.).
INSPECT EXHAUST VALVE SEAT
1. Apply a light coat of Prussian blue (or white lead) to the valve face.
2. Lightly press the valve face against the valve seat.
3. Check the valve face and valve seat by using to the following procedure.
  
  Fig 40: Identifying Exhaust Valve Seat Width
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.).
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: View Of 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.
  
  Fig 42: Identifying Cutters Angles For Correcting Valve Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Width
  
  1.0 to 1.4 mm (0.039 to 0.055 in.)
3. Handrub the valve and valve seat with an abrasive compound.
4. Check the valve seating position.
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: View Of 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.
  
  Fig 44: Identifying Cutters Angles For Correcting Valve Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Width
  
  1.2 to 1.6 mm (0.047 to 0.063 in.)
3. Handrub the valve and valve seat with an abrasive compound.
4. Check the valve seating position.
INSPECT INNER COMPRESSION SPRING
1. Using vernier calipers, measure the free length of the inner compression spring.
  
  Fig 45: View Of Measuring Free Length Of Inner Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Free length
  
  57.46 mm (2.2622 in.)
  
  If the free length is not as specified, replace the spring.
2. Using a steel square, measure the deviation of the inner compression spring.
  
  Fig 46: Measuring Deviation Of Inner Compression Spring Using Steel Square
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum deviation
  
  1.0 mm (0.039 in.)
  
  Maximum angle (reference)
  
  2°
  
  If the deviation is greater than the maximum, replace the spring.

INSPECT VALVE GUIDE BUSH OIL CLEARANCE

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

Fig 47: Measuring Inside Diameter Of Guide Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

Maximum oil clearance

Item	Clearance
Intake	0.08 mm (0.0032 in.)
Exhaust	0.01 mm (0.00039 in.)

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. Refer to REASSEMBLY .
  2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
    
    Fig 48: Checking Camshaft Thrust Clearance While Moving It Back And Forth
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    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 camshaft housing. If the thrust surface is damaged, replace the camshaft.
2. Inspect the LH bank camshaft thrust clearance.
  1. Install the LH bank camshafts. Refer to 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 camshaft housing. 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.

Fig 49: Identifying Plastigage
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the bearing caps. Refer to REASSEMBLY .
NOTE:
Do not turn the camshaft.
Remove the bearing caps. Refer to DISASSEMBLY .

Measure the Plastigage at its widest point.

Fig 50: Measuring Plastigage At Its Widest Point

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard oil clearance

Item	Oil Clearance
No. 1 journal	0.031 to 0.078 mm (0.0012 to 0.0031 in.)
Other journal	0.025 to 0.062 mm (0.00098 to 0.0024 in.)

Maximum oil clearance

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.

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.

Fig 51: Laying Strip Of Plastigage Across Each Of Camshaft Journals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the bearing caps. Refer to REASSEMBLY .
NOTE:
Do not turn the camshaft.
Remove the bearing caps. Refer to DISASSEMBLY .

Measure the Plastigage at its widest point.

Fig 52: Measuring Plastigage At Its Widest Point

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard oil clearance

Item	Oil Clearance
No. 1 journal	0.031 to 0.078 mm (0.0012 to 0.0031 in.)
Other journal	0.025 to 0.062 mm (0.00098 to 0.0024 in.)

Maximum oil clearance

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.

INSPECT CONNECTING ROD THRUST CLEARANCE
1. Install the connecting rod cap. Refer to REASSEMBLY .
2. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
  
  Fig 53: View Of Measuring Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard thrust clearance
  
  0.25 to 0.40 mm (0.0098 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.
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.

Fig 55: Identifying Front Mark Of Connecting Rod Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the connecting rod cap. Refer to REASSEMBLY .
NOTE:
Do not turn the crankshaft.
Remove the 2 bolts and connecting rod cap. Refer to DISASSEMBLY .

Measure the Plastigage at its widest point.

Fig 56: Measuring Plastigage At Its Widest Point

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard oil clearance

0.042 to 0.068 mm (0.0017 to 0.0027 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 and 4 mark on its surface.

Connecting rod diameter

Mark	Diameter
1	51.000 to 51.006 mm (2.0079 to 2.0081 in.)
2	51.007 to 51.012 mm (2.0081 to 2.0083 in.)
3	51.013 to 51.018 mm (2.0084 to 2.0086 in.)
4	51.019 to 51.024 mm (2.0086 to 2.0088 in.)

Connecting rod bearing center wall thickness

Mark	Thickness
1	1.484 to 1.487 mm (0.0584 to 0.0585 in.)
2	1.487 to 1.490 mm (0.0585 to 0.0587 in.)
3	1.490 to 1.493 mm (0.0587 to 0.0588 in.)
4	1.493 to 1.496 mm (0.0588 to 0.0589 in.)

Crankshaft pin diameter

47.992 to 48.000 mm (1.8894 to 1.8898 in.)

Completely remove the Plastigage.

INSPECT CRANKSHAFT THRUST CLEARANCE
1. Install the main bearing cap. Refer to REASSEMBLY .
2. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
  
  Fig 57: Checking Crankshaft Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard thrust clearance
  
  0.040 to 0.240 mm (0.00158 to 0.00944 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.)
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.
  
  Fig 58: Checking Warpage Of Contact Surface Of Cylinder Head Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum warpage
  
  0.07 mm (0.0028 in.)
  
  If the warpage is greater than the maximum, replace the cylinder block.
INSPECT CYLINDER BORE
1. Visually check the cylinder for vertical scratches.
  
  Fig 59: Checking Cylinder For Vertical Scratches
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If deep scratches are present, rebore all the 6 cylinders. If necessary, replace the cylinder block.
2. Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
  
  Fig 60: Measuring Cylinder Bore Diameter Using Cylinder Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard diameter
  
  83.000 to 83.012 mm (3.2677 to 3.2682 in.)
  
  Maximum diameter
  
  83.200 mm (3.2756 in.)
  
  If the average diameter of 4 positions is greater than the maximum, replace the cylinder block.
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.
  
  Fig 61: Measuring Piston Diameter At Right Angles Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Distance
  
  14.3 mm (0.563 in.)
  
  Standard diameter
  
  82.966 to 82.996 mm (3.2664 to 3.2676 in.)
  
  Minimum diameter
  
  82.836 mm (3.2613 in.)
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
  
  0.014 to 0.036 mm (0.0006 to 0.0014 in.)
  
  Maximum oil clearance
  
  0.090 mm (0.0035 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.

Fig 62: Measuring Clearance Between New Piston Ring & Wall Of Ring Groove Using Feeler Gauge

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Ring groove clearance

Item	Clearance
No. 1	0.040 to 0.080 mm (0.0016 to 0.0031 in.)
No. 2	0.030 to 0.070 mm (0.0012 to 0.0028 in.)
Oil	0.020 to 0.065 mm (0.0008 to 0.0026 in.)

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

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.

Fig 64: Checking Piston Ring End Gap

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard end gap

Item	End Gap
No. 1	0.28 to 0.38 mm (0.0110 to 0.0150 in.)
No. 2	0.35 to 0.45 mm (0.0138 to 0.0178 in.)
Oil	0.13 to 0.38 mm (0.0051 to 0.0150 in.)

Maximum end gap

Item	End Gap
No. 1	0.50 mm (0.0197 in.)
No. 2	0.80 mm (0.0315 in.)
Oil	0.65 mm (0.0256 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.

INSPECT PISTON PIN OIL CLEARANCE

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

Fig 65: Measuring Inside Diameter Of Piston Pin Hole Using Caliper Gauge

Piston pin hole inside diameter

Mark	Diameter
A	21.998 to 22.001 mm (0.8661 to 0.8662 in.)
B	22.001 to 22.004 mm (0.8662 to 0.8663 in.)
C	22.004 to 22.007 mm (0.8663 to 0.8664 in.)

Using a micrometer, measure the piston pin diameter.

Fig 66: Measuring Piston Pin Diameter

Piston pin diameter

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

-0.002 to 0.004 mm (-0.00007 to 0.0001 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.

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

Fig 67: Checking Inside Diameter Of Connecting Rod Bushing

Bushing inside diameter

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	22.011 to 22.014 mm (0.8666 to 0.8667 in.)

Subtract the piston pin diameter measurement from the bushing inside diameter measurement.

Fig 68: Identifying Piston Pin, Bushing And Connecting Rod
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

INSPECT CONNECTING ROD
1. Using a rod aligner and feeler gauge, check the connecting rod alignment.
  
  Fig 69: Checking Connecting Rod Alignment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
  2. Check for twist.
    
    Fig 70: Checking Connecting Rod For Twist
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    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.
INSPECT CONNECTING ROD BOLT
1. Using vernier calipers, measure the tension portion diameter of the bolt.
  
  Fig 71: Identifying Tension Portion Diameter Of Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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 the V-blocks.
  3. Using a dial indicator, measure the circle runout at the center journal.
    
    Fig 72: Measuring Circle Runout At Center Journal Using Dial Indicator
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Maximum circle runout
    
    0.06 mm (0.0024 in.)
    
    If the circle runout is greater than the maximum, replace the crankshaft.
2. Inspect the main journals.
  1. Using a micrometer, measure the diameter of each main journal.
    
    Fig 73: Checking Main Journal For Taper And Out-Of Round
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    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.
3. Inspect the crank pin.
  1. Using a micrometer, measure the diameter of each crank pin.
    
    Fig 74: Checking Crank Pin For Taper And Out-Of Round
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Crankshaft pin diameter
    
    47.992 to 48.000 mm (1.8894 to 1.8898 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.

INSPECT CRANKSHAFT OIL CLEARANCE

Check the crank journal and bearing for pitting and scratches.
Install the crankshaft bearing. Refer to REASSEMBLY .
Place the crankshaft on the cylinder block.
Lay a strip of Plastigage across each journal.

Fig 75: Laying Strip Of Plastigage Across Each Journal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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. Refer to REASSEMBLY .
NOTE:
Do not turn the crankshaft.
Remove the main bearing caps. Refer to DISASSEMBLY .
Measure the Plastigage at its widest point.

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

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.

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 size of standard bearings, marked "1", "2", "3", "4" and "5" accordingly.

Fig 77: Identifying Journal Bearing Diameter

JOURNAL BEARINGS:

Cylinder block + 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")

Crankshaft main journal diameter

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.)

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)

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)

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)

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.
  
  Fig 78: Identifying Crankshaft Bearing Cap Set Bolt Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard diameter
  
  10.8 to 11.0 mm (0.4252 to 0.4331 in.)
  
  Minimum diameter
  
  10.7 mm (0.4213 in.)
  
  Measuring Point
  
  47 mm (1.85 in.)
  
  If the diameter is less than the minimum, replace the bolt.