2Tr-Fe Engine Mechanical. Engine Unit Inspection

Engine Unit -- Inspection

1. INSPECT CHAIN SUB-ASSEMBLY

Pull the chain sub-assembly with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.

Using a vernier caliper, measure the length of 16 links.
Maximum chain elongation:
147.5 mm (5.81 in.)
Text in Illustration
*a
Measuring Area
If the elongation is more than the maximum, replace the chain sub-assembly.
NOTICE:
Perform the measurement at 3 random places.

Text in Illustration
*a	Measuring Area

2. INSPECT NO. 2 CHAIN SUB-ASSEMBLY

Pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33.0 lbf).

Using a vernier caliper, measure the length of 16 links.
Maximum chain elongation:
123.6 mm (4.87 in.)
If the elongation is more than the maximum, replace the No. 2 chain sub-assembly.
NOTICE:
Perform the measurement at 3 random places.

3. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly.
Text in Illustration
*a
Plunger
*b
Stopper Plate

Text in Illustration
*a	Plunger
*b	Stopper Plate

4. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

Move the stopper plate downward to release the lock. Push the plunger and check that it moves smoothly.
Text in Illustration
*a
Plunger
*b
Stopper Plate

Text in Illustration
*a	Plunger
*b	Stopper Plate

5. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

Measure the distance between the most worn out camshaft timing gear tip and the beginning of the worn area below the tip.
Minimum distance:
1.0 mm (0.0394 in.)
Text in Illustration

Worn Area
If the distance is less than the minimum, replace the camshaft timing gear assembly.
If the worn area is too small or difficult to distinguish from a normal area, perform the following 2 steps.

Text in Illustration
	Worn Area

Wrap the chain sub-assembly around the camshaft timing gear assembly.

Using a vernier caliper, measure the sprocket diameter with the chain sub-assembly.
Minimum sprocket diameter (with chain):
113.8 mm (4.48 in.)
HINT:
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the chain sub-assembly and camshaft timing gear assembly.

6. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

Measure the distance between the most worn out camshaft timing gear tip and the beginning of the worn area below the tip.
Minimum distance:
1.0 mm (0.0394 in.)
Text in Illustration

Worn Area
If the distance is less than the minimum, replace the camshaft timing exhaust gear assembly.
If the worn area is too small or difficult to distinguish from a normal area, perform the following 2 steps.

Text in Illustration
	Worn Area

Wrap the chain sub-assembly around the camshaft timing exhaust gear assembly.

Using a vernier caliper, measure the sprocket diameter with the chain sub-assembly.
Minimum sprocket diameter (with chain):
113.8 mm (4.48 in.)
HINT:
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the chain sub-assembly and camshaft timing exhaust gear assembly.

7. INSPECT CRANKSHAFT TIMING GEAR

Measure the distance between the most worn out crankshaft timing gear tip and the beginning of the worn area below the tip.
Minimum distance:
1.0 mm (0.0394 in.)
Text in Illustration

Worn Area
If the distance is less than the minimum, replace the crankshaft timing gear.
If the worn area is too small or difficult to distinguish from a normal area, perform the following 2 steps.

Text in Illustration
	Worn Area

Wrap the chain sub-assembly around the crankshaft timing gear.

Using a vernier caliper, measure the sprocket diameter with the chain sub-assembly.
Minimum sprocket diameter (with chain):
59.4 mm (2.34 in.)
HINT:
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the chain sub-assembly and crankshaft timing gear.

8. INSPECT CHAIN TENSIONER SLIPPER

Using a vernier caliper, measure the chain tensioner slipper wear.
Maximum wear:
2.0 mm (0.0787 in.)
Text in Illustration
*a
Wear
If the wear is more than the maximum, replace the chain tensioner slipper.

Text in Illustration
*a	Wear

9. INSPECT NO. 1 CHAIN VIBRATION DAMPER

Using a vernier caliper, measure the No. 1 chain vibration damper wear.
Maximum wear:
2.0 mm (0.0787 in.)
Text in Illustration
*a
Wear
If the wear is more than the maximum, replace the No. 1 chain vibration damper.

Text in Illustration
*a	Wear

10. INSPECT TIMING CHAIN GUIDE

Using a vernier caliper, measure the timing chain guide wear.
Maximum wear:
0.5 mm (0.0197 in.)
Text in Illustration

Wear
If the wear is more than the maximum, replace the timing chain guide.

Text in Illustration
	Wear

11. INSPECT NO. 2 CRANKSHAFT TIMING SPROCKET

Wrap the chain around the No. 2 crankshaft timing sprocket.

Using a vernier caliper, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain):
96.7 mm (3.81 in.)
HINT:
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the No. 2 chain sub-assembly and No. 2 crankshaft timing sprocket.

12. INSPECT BALANCESHAFT DRIVE GEAR SUB-ASSEMBLY

Wrap the No. 2 chain sub-assembly around the balanceshaft drive gear sub-assembly.

Using a vernier caliper, measure the sprocket diameter with the No. 2 chain sub-assembly.
Minimum sprocket diameter (with chain):
75.9 mm (2.99 in.)
HINT:
The vernier caliper must contact the chain rollers for the measurement.
If the diameter is less than the minimum, replace the No. 2 chain sub-assembly and balanceshaft drive gear sub-assembly.

13. INSPECT NO. 2 CHAIN VIBRATION DAMPER

Using a vernier caliper, measure the No. 2 chain vibration damper wear.
Maximum wear:
1.0 mm (0.0394 in.)
Text in Illustration
*a
Wear
If the wear is more than the maximum, replace the No. 2 chain vibration damper.

Text in Illustration
*a	Wear

14. INSPECT NO. 3 CHAIN VIBRATION DAMPER

Using a vernier caliper, measure the No. 3 chain vibration damper wear.
Maximum wear:
1.0 mm (0.0394 in.)
Text in Illustration
*a
Wear
If the wear is more than the maximum, replace the No. 3 chain vibration damper.

Text in Illustration
*a	Wear

15. INSPECT NO. 4 CHAIN VIBRATION DAMPER

Using a vernier caliper, measure the No. 4 chain vibration damper wear.
Maximum wear:
1.0 mm (0.0394 in.)
Text in Illustration
*a
Wear
If the wear is more than the maximum, replace the No. 4 chain vibration damper.

Text in Illustration
*a	Wear

16. INSPECT CYLINDER HEAD SET BOLT

Using a vernier caliper, measure the diameter of the most elongated threads in the measuring area.
Standard outside diameter:
10.76 to 10.97 mm (0.424 to 0.432 in.)
Minimum outside diameter:
10.40 mm (0.409 in.)
Distance:
30 mm (1.18 in.)
Text in Illustration
*a
Measuring area
*b
Distance
If a visual check reveals no excessively thin areas, check the center of the measuring area (see illustration) and find the area that has the smallest diameter.
If the diameter is less than the minimum, replace the cylinder head bolt.

Text in Illustration
*a	Measuring area
*b	Distance

17. INSPECT VALVE LASH ADJUSTER ASSEMBLY

NOTICE:

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

Place the lash adjuster into a container full of new engine oil.
Text in Illustration
*a
CORRECT
*b
INCORRECT
*c
Taper Part
*d
Plunger
*e
Low Pressure Chamber
*f
Check Ball
*g
High Pressure Chamber

Text in Illustration
*a	CORRECT
*b	INCORRECT
*c	Taper Part
*d	Plunger
*e	Low Pressure Chamber
*f	Check Ball
*g	High Pressure Chamber

Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.
SST
09276-75010

Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times.

Check the movement of the plunger and bleed air.
OK:
Plunger moves up and down.
NOTICE:
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 will not bleed.

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.

18. INSPECT CAMSHAFT

Check the camshaft runout.
1. Place the camshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
  Maximum circle runout:
  0.03 mm (0.00118 in.)
  If the circle runout is more than the maximum, replace the camshaft.

Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
42.855 to 42.955 mm (1.687 to 1.691 in.)
Minimum cam lobe height:
42.855 mm (1.687 in.)
If the cam lobe height is less than the minimum, replace the camshaft.

Using a micrometer, measure the journal diameter.
Standard Journal Diameter:
Item
Specified Condition
No. 1 journal
35.949 to 35.965 mm (1.415 to 1.416 in.)
Other journal
26.959 to 26.975 mm (1.061 to 1.062 in.)
If the journal diameter is not as specified, check the oil clearance.

19. INSPECT NO. 2 CAMSHAFT

Check the No. 2 camshaft runout.
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:
  0.03 mm (0.00118 in.)
  If the circle runout is more than the maximum, replace the No. 2 camshaft.

Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
42.854 to 42.954 mm (1.687 to 1.691 in.)
Minimum cam lobe height:
42.854 mm (1.687 in.)
If the cam lobe height is less than the minimum, replace the No. 2 camshaft.

Using a micrometer, measure the journal diameter.
Standard Journal Diameter:
Item
Specified Condition
No. 1 journal
35.949 to 35.965 mm (1.415 to 1.416 in.)
Other journal
26.959 to 26.975 mm (1.061 to 1.062 in.)
If the journal diameter is not as specified, check the oil clearance.

20. INSPECT CAMSHAFT THRUST CLEARANCE

Install the camshafts (LandCruiser RM000000YMY02TX_01_0005.html).

Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance:
0.10 to 0.24 mm (0.00394 to 0.00945 in.)
Maximum thrust clearance:
0.26 mm (0.0102 in.)
If the thrust clearance is more than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

21. INSPECT CAMSHAFT OIL CLEARANCE

Clean the bearing caps and camshaft journals.

Place the camshafts on the cylinder head.

Lay a strip of Plastigage across each of the camshaft journals.
Text in Illustration
*a
Plastigage

Install the bearing caps (LandCruiser RM0000017OI01DX_01_0114.html).
NOTICE:
Do not turn the camshafts.

Remove the bearing caps (LandCruiser RM0000017KN01DX_01_0106.html).

Measure the Plastigage at its widest point.
Standard Oil Clearance:
Item
Specified Condition
No. 1 journal
0.035 to 0.072 mm (0.00138 to 0.00283 in.)
Other journals
0.025 to 0.062 mm (0.000984 to 0.00244 in.)
Maximum oil clearance:
0.08 mm (0.00315 in.)
Text in Illustration
*a
Plastigage
If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the cylinder head sub-assembly.

Completely remove the Plastigage.

22. INSPECT EXHAUST MANIFOLD

Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts the cylinder head.
Maximum warpage:
0.7 mm (0.0276 in.)
If the warpage is more than the maximum, replace the exhaust manifold.

Item	Specified Condition
No. 1 journal	35.949 to 35.965 mm (1.415 to 1.416 in.)
Other journal	26.959 to 26.975 mm (1.061 to 1.062 in.)