Engine Unit: Inspection

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
1. Install the camshaft housing to the cylinder head sub-assembly LH (for Bank 1).
  1. Place the camshaft housing onto the cylinder head sub-assembly LH
  2. Temporarily tighten the camshaft housing with the 3 bolts in the sequence shown in the illustration.
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
    
    Fig 1: Locating Tightening Sequence Of Camshaft Housing Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Fully tighten the 3 bolts in the sequence shown in the illustration.
    Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf)
2. Install the camshaft housing to the cylinder head sub-assembly (for Bank 2).
  1. Place the camshaft housing onto the cylinder head sub-assembly.
  2. Temporarily tighten the camshaft housing with the 3 bolts in the sequence shown in the illustration.
    Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  3. Fully tighten the 3 bolts in the sequence shown in the illustration.
    Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf)
  Fig 2: Locating Tightening Sequence Of Camshaft Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the No. 4 camshaft
  HINT:
  
  Only install the exhaust camshaft.
4. Install the No. 2 camshaft.
  HINT
  
  Only install the exhaust camshaft
5. Install the camshaft bearing cap (See INSTALLATION ) (for Bank 1)
6. Install the camshaft bearing cap (See INSTALLATION ) (for Bank 2).
7. Apply a light coat of engine oil to the camshaft and camshaft timing exhaust gear assembly.
8. Align and insert the knock pin of the camshaft into the pin hole of the camshaft timing exhaust gear assembly
  NOTE:
  - Do not forcefully push in the camshaft timing exhaust gear assembly. This may cause the camshaft knock pin tip to damage the camshaft timing exhaust gear assembly.
    
    Fig 3: Identifying Camshaft Knock Pin And Camshaft Timing Exhaust Gear Pin Hole
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Be sure not to remove the other 4 bolts. If removed, replace the camshaft timing exhaust gear assembly.
9. Apply a light coat of engine oil to the threads and under the head of the bolt.
  
  Fig 4: Identifying Camshaft Timing Exhaust Gear Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing exhaust gear assembly with the bolt.
  Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
11. Remove the camshaft bearing cap (See REMOVAL ) (for Bank 1)
12. Remove the camshaft bearing cap (See REMOVAL ). (for Bank 2)
13. Check the lock of the camshaft timing exhaust gear assembly
  1. Make sure that the camshaft timing exhaust gear assembly is locked
  Fig 5: Installing Camshaft Timing Exhaust Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Release the lock pin.
  1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
  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 6: Identifying Oil Paths Of Cam Journal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Apply approximately 200 kPa (2.0 kgf/cm² , 28 psi) of air pressure to the 2 broken paths (the advance side path and the retard side path).
    CAUTION: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.
    
    Fig 7: Applying Air Pressure To Broken Paths (Advance Side Path And Retard Side Path)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Check that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path.
    HINT
    
    This operation releases the lock pin for the most retarded position
    
    Fig 8: Checking Camshaft Timing Exhaust Gear Assembly Rotation
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. When the camshaft timing exhaust gear assembly reaches the most retarded position, release the air pressure from the advance side path and retard side path, in that order
  NOTE: Do not release the air pressure from the retard side path first. The gear may abruptly shift in the advance direction and break the lock pin.
15. Check for smooth rotation
  1. Turn the camshaft timing exhaust gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most advanced position Make sure that the gear turns smoothly.
  NOTE: Do not use air pressure to check for smooth rotation.
16. Check the lock in the most advanced position.
  1. Confirm that the camshaft timing exhaust gear assembly is locked at the most advanced position
17. Install the No 4 camshaft
  HINT
  
  Only install the exhaust camshaft.
18. Install the No. 2 camshaft
  HINT
  
  Only install the exhaust camshaft
19. Install the camshaft bearing cap (See INSTALLATION ) (for Bank 1).
20. Install the camshaft bearing cap (See INSTALLATION ) (for Bank 2)
21. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.
22. Remove the camshaft bearing cap (See REMOVAL ) (for Bank 1)
23. Remove the camshaft bearing cap (See REMOVAL ) (for Bank 2)
  
  Fig 9: Loosening Camshaft Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. Remove the flange bolt and camshaft timing exhaust gear assembly.
  NOTE: Be sure not to remove the other 4 bolts.
  
  Fig 10: Identifying Camshaft Timing Exhaust Gear Assembly Flange Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. Remove the camshaft housing from the cylinder head sub-assembly LH. (for Bank 1)
  1. Remove the 3 bolt and camshaft housing from the cylinder head sub-assembly LH
  Fig 11: Locating Camshaft Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. Remove the camshaft housing from the cylinder head sub-assembly (for Bank 2)
  1. Remove the 3 bolt and camshaft housing from the cylinder head sub-assembly.
  Fig 12: Locating Camshaft Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Turn the roller by hand to check that it turns smoothly
  If the roller does not turn smoothly, replace the No 1 valve rocker arm sub-assembly.
  
  Fig 13: Turning Roller
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CAMSHAFT

Inspect the camshaft for runout.
1. Place the camshaft on V-blocks
2. Using a dial indicator, measure the circle runout at the center journal.
  Maximum circle runout:
  
  0.04 mm (0.00157 in.)
  
  If the circle runout is greater than the maximum, replace the camshaft
  
  Fig 14: Measuring Camshaft Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT.
  
  Check the oil clearance after replacing the camshaft

Using a micrometer, measure the cam lobe height

Standard Cam Lobe Height

CAM LOBE HEIGHT SPECIFICATION

Item	Specified Condition
Intake	44.953 to 45.103 mm (1.7698 to 1.7757 in.)
Exhaust	44.576 to 44.726 mm (1.7549 to 1.7609 in.)

Minimum Cam Lobe Height

CAM LOBE HEIGHT SPECIFICATION

Item	Specified Condition
Intake	44.903 mm (1.7678 in.)
Exhaust	44 526 mm (1 7530 in.)

Fig 15: Measuring Cam Lobe Height

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the cam lobe height is less than the minimum, replace the camshaft

Using a micrometer, measure the journal diameter.

Standard Journal Diameter

JOURNAL DIAMETER SPECIFICATION

Item	Specified Condition
No. 1 journal	29.956 to 29 970 mm (1.1794 to 1.1799 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 16: Measuring Journal Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CAMSHAFT OIL CLEARANCE

Clean the bearing caps, camshaft housing and camshaft journals
Install the camshaft housing onto the cylinder head sub-assembly LH (for Bank 1).
1. Place the camshaft housing to the cylinder head sub-assembly LH.
2. Temporarily tighten the camshaft housing with the 3 bolt in the sequence shown in the illustration
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. Fully tighten the 3 bolts in the sequence shown in the illustration
  Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf)
Fig 17: Locating Tightening Sequence Of Camshaft Housing Bolts (For Bank 1)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the camshaft housing to the cylinder head sub-assembly (for bank 2).
1. Place the camshaft housing onto the cylinder head sub-assembly
2. Temporarily tighten the camshaft housing with the 3 bolt in the sequence shown in the illustration.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. Fully tighten the 3 bolts in the sequence shown in the illustration
  Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf)
Fig 18: Locating Tightening Sequence Of Camshaft Housing Bolts (For Bank 2)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Place the camshafts on the cylinder heads.
Lay a strip of Plastigage across each of the camshaft journals
Install the camshaft bearing cap (See INSTALLATION ) (for Bank 1).
NOTE: Do not turn the camshaft.
Install the camshaft bearing cap (See INSTALLATION ) (for Bank 2).
NOTE: Do not turn the camshaft.

Fig 19: Identifying Laying Strip Of Plastigage Across Camshaft Journals
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the camshaft bearing cap (See REMOVAL ) (for Bank 1)
Remove the camshaft bearing cap (See REMOVAL ) (for Bank 2)

Measure the Plastigage at its widest point.

Standard Oil Clearance

OIL CLEARANCE SPECIFICATION

Item	Specified Condition
No. 1 journal	0.030 to 0.069 mm (0.00118 to 0 00272 in.)
Other journal	0.025 to 0 062 mm (0.000984 to 0 00244 in.)

Maximum Oil Clearance

OIL CLEARANCE SPECIFICATION

Item	Specified Condition
No 1 journal	0.09 mm (0.00354 in.)
Other journal	0 09 mm (0.00354 in.)

Fig 20: Measuring Plastigage

If the oil clearance is greater than the maximum, replace the camshaft If necessary, replace the cylinder head sub-assembly

Remove the camshafts from the cylinder heads.
Remove the camshaft housing from the cylinder head sub-assembly LH. (for Bank 1)
1. Remove the 3 bolt and camshaft housing from the cylinder head sub-assembly LH.
Fig 21: Locating Camshaft Housing Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the camshaft housing from the cylinder head sub-assembly (for Bank 2)
1. Remove the 3 bolt and camshaft housing from the cylinder head sub-assembly.
Fig 22: Locating Camshaft Housing Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
1. Using a vernier caliper, measure the width of the camshaft timing gear assembly's eccentric shaft cutout
  Standard width:
  
  5.9 to 6.2 mm (0.232 to 0.244 in.)
  
  Maximum width:
  
  6.7 mm (0.264 in.)
  
  If the result is greater than the maximum value, replace the camshaft timing gear assembly.
  
  Fig 23: Rotating Keyway Part Of Camshaft Timing Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Rotate the keyway part of the camshaft timing gear assembly's eccentric shaft by hand.
  Standard:
  
  Rotates smoothly
  
  If the result is not as specified, replace the camshaft timing gear assembly
  NOTE:
  - Do not drop the camshaft timing gear assembly. If dropped, replace it.
  - Do not disassemble the camshaft timing gear assembly. If disassembled, replace it.
INSPECT CYLINDER HEAD SET BOLT
1. Using a vernier caliper, measure the minimum diameter of the elongated thread at the measuring point
  Standard outside diameter:
  
  10.85 to 11.00 mm (0.427 to 0.433 in.)
  
  Minimum outside diameter:
  
  10.6 mm (0.417 in.)
  
  Measuring point:
  
  90 mm (3.54 in.) for intake side bolt
  
  85 mm (3.35 in.) for exhaust side bolt
Fig 24: Identifying Cylinder Head Set Bolt Measuring Point
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT
- If a visual check shows no excessively thin areas, check the center of the bolt (see illustration above) and find the area that has the smallest diameter.
- If the diameter is less than the minimum, replace the cylinder head bolt.
INSPECT NO. 1 CHAIN SUB-ASSEMBLY
1. Using a spring scale, pull the No. 1 chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration
2. Using a vernier caliper, measure the length of 15 pins.
  Maximum chain elongation:
  
  136.9 mm (5.39 in.)
  
  If the elongation is greater than the maximum, replace the No 1 chain sub-assembly.
  
  NOTE: Perform the measurement at 3 random places.
  
  Fig 25: Inspecting No 1 Chain Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 CHAIN SUB-ASSEMBLY
1. Using a spring scale, pull the No 2 chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.
2. Using a vernier caliper, measure the length of 15 pins
  Maximum chain elongation:
  
  137.6 mm (5.42 in.)
  
  If the elongation is greater than the maximum, replace the No 2 chain sub-assembly
  
  NOTE: Perform the measurement at 3 random places.
  
  Fig 26: Inspecting No 2 Chain Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT TIMING GEAR
1. Wrap the No 1 chain sub-assembly around the sprocket.
2. Using a vernier caliper, measure the sprocket diameter with the No. 1 chain sub-assembly
  Minimum sprocket diameter (w/ chain sub-assembly):
  
  61.4 mm (2.42 in.)
  
  HINT:
  
  The vernier caliper must contact the No. 1 chain sub-assembly rollers for the measurement If the diameter is less than the minimum, replace the No. 1 chain sub-assembly and crankshaft timing gear
  
  Fig 27: Measuring Crankshaft Sprocket Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CRANKSHAFT TIMING SPROCKET LH
1. Wrap the No 1 chain sub-assembly around the crankshaft timing sprocket LH
2. Using a vernier caliper, measure the crankshaft timing sprocket LH diameter with the No 1 chain sub-assembly.
  Minimum crankshaft timing sprocket LH diameter (w/ No. 1 chain sub-assembly):
  
  61.4 mm (2.42 in.)
  
  Fig 28: Measuring Crankshaft Timing Sprocket Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: The vernier caliper must contact the No. 1 chain sub-assembly rollers for the measurement. If the diameter is less than the minimum, replace the No. 1 chain sub-assembly and crankshaft timing sprocket LH
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 No 1 chain tensioner assembly
Fig 29: Inspecting No 1 Chain Tensioner Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
1. Check that the plunger moves smoothly
2. Measure the worn depth of the No. 2 chain tensioner assembly
  Maximum depth:
  
  0.9 mm (0.0354 in.)
  
  If the depth is greater than the maximum, replace the No 2 chain tensioner assembly
  
  Fig 30: Inspecting No 2 Chain Tensioner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY
1. Check that the plunger moves smoothly
2. Measure the worn depth of the No. 3 chain tensioner assembly
  Maximum depth:
  
  0.9 mm (0.0354 in.)
  
  If the depth is greater than the maximum, replace the No 3 chain tensioner assembly
  
  Fig 31: Inspecting No 3 Chain Tensioner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CHAIN TENSIONER SLIPPER
1. for Bank 1
  1. Measure the worn depth of the chain tensioner slipper
    Maximum depth:
    
    1.0 mm (0.0394 in.)
    
    If the depth is greater than the maximum, replace the chain tensioner slipper
    
    Fig 32: Identifying Worn Depth Of Chain Tensioner Slipper (For Bank 1)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. for Bank 2
  1. Measure the worn depth of the chain tensioner slipper
    Maximum depth:
    
    1.0 mm (0.0394 in.)
    
    If the depth is greater than the maximum, replace the chain tensioner slipper
    
    Fig 33: Identifying Worn Depth Of Chain Tensioner Slipper (For Bank 2)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 CHAIN VIBRATION DAMPER
1. for Bank 1:
  1. Measure the worn depth of the No. 1 chain vibration damper
    Maximum depth:
    
    1.0 mm (0.0394 in.)
    
    If the depth is greater than the maximum, replace the No. 1 chain vibration damper.
    
    Fig 34: Identifying Worn Depth Of No 1 Chain Vibration Damper (For Bank 1)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. for Bank 2.
  1. Measure the worn depth of the No 1 chain vibration damper.
    Maximum depth:
    
    1.0 mm (0.0394 in.)
    
    If the depth is greater than the maximum, replace the No 1 chain vibration damper.
INSPECT CYLINDER HEAD SUB-ASSEMBLY (See INSPECTION )

Fig 35: Identifying Worn Depth Of No 1 Chain Vibration Damper (For Bank 2)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH
1. Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts the cylinder head sub-assembly LH
  Maximum warpage:
  
  0.5 mm (0.0197 in.)
  
  If the warpage is greater than the maximum, replace the exhaust manifold sub-assembly LH.
  
  Fig 36: Inspecting Exhaust Manifold Sub-Assembly LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
1. Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts the cylinder head sub-assembly.
  Maximum warpage:
  
  0.5 mm (0.0197 in.)
  
  If the warpage is greater than the maximum, replace the exhaust manifold sub-assembly RH.
  
  Fig 37: Inspecting Exhaust Manifold Sub-Assembly RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002