Engine Unit Inspection

Install the balanceshafts (CAMRY_ACV40 RM000000YI700VX.html).

Using a dial indicator, measure the thrust clearance while moving the balanceshaft back and forth.

Standard thrust clearance:

0.05 to 0.09 mm (0.0020 to 0.0035 in.)

Maximum thrust clearance:

0.09 mm (0.0035 in.)

Clean each bearing and journal.

Check each bearing and journal for pitting and scratches.
If a bearing or journal is damaged, replace the bearings. If necessary, replace the balanceshaft.

Place the No. 1 and No. 2 balanceshafts onto the crankcase.

Lay a strip of Plastigage across each journal.

Install the balanceshaft housing (CAMRY_ACV40 RM000000YI700VX.html).

NOTICE:

Do not turn the balanceshafts.

Remove the balanceshafts (CAMRY_ACV40 RM000000YI600VX.html).

Measure the Plastigage at its widest point.

Standard oil clearance:

0.004 to 0.049 mm (0.0002 to 0.0019 in.)

Maximum oil clearance:

0.049 mm (0.0019 in.)

NOTICE:

Remove the Plastigage completely after the measurement.

If replacing a bearing, select a new one with the same number.

Standard balanceshaft housing journal bore diameter:

Item	Specified Condition
Mark 1	26.000 to 26.006 mm (1.0236 to 1.0239 in.)
Mark 2	26.007 to 26.012 mm (1.0239 to 1.0241 in.)
Mark 3	26.013 to 26.018 mm (1.0241 to 1.0243 in.)

Standard bearing center wall thickness:

Item	Specified Condition
Mark 1	1.486 to 1.489 mm (0.05850 to 0.05862 in.)
Mark 2	1.490 to 1.492 mm (0.05866 to 0.05874 in.)
Mark 3	1.493 to 1.495 mm (0.0588 to 0.0589 in.)

Standard balanceshaft journal diameter:

Item	Journal diameter
Mark 1	22.985 to 23.000 mm (0.9049 to 0.9055 in.)
Mark 2	22.985 to 23.000 mm (0.9049 to 0.9055 in.)
Mark 3	22.985 to 23.000 mm (0.9049 to 0.9055 in.)

Inspect the balanceshaft housing bolts.

1. Using vernier calipers, measure the length of the bolts from the seat to the end.
   

   Standard bolt length:

   58.3 to 59.7 mm (2.295 to 2.350 in.)
   

   Maximum bolt length:

   60.3 mm (2.374 in.)
   

   If the bolt length is greater than the maximum, replace the balanceshaft housing bolt.
   

Pull the chain with a force of 140 N (14.3 kgf, 31.5 lbf) as shown in the illustration.

Using vernier calipers, measure the length of 15 links.

Maximum chain elongation:

114.5 mm (4.508 in.)

NOTICE:

Perform the measurement at 3 random places. Use the average of the measurements.

Pull the chain with a force of 140 N (14.3 kgf, 31.5 lbf) as shown in the illustration.

Using vernier calipers, measure the length of 15 links.

Maximum chain elongation:

102.2 mm (4.024 in.)

NOTICE:

Perform the measurement at 3 random places. Use the average of the measurements.

Wrap the chain around the sprocket.

Using vernier calipers, measure the sprocket diameter with the chain wrapped around.

Minimum gear diameter (with chain):

48.2 mm (1.898 in.)

NOTICE:

The vernier calipers must be in contact with the chain rollers when measuring.

Wrap the chain around the sprocket.

Using vernier calipers, measure the sprocket diameter with the chain wrapped around.

Minimum gear diameter (with chain):

48.2 mm (1.898 in.)

NOTICE:

The vernier calipers must be in contact with the chain rollers when measuring.

Wrap the chain around the sprocket.

Using vernier calipers, measure the sprocket diameter with the chain wrapped around.

Minimum gear diameter (with chain):

97.3 mm (3.831 in.)

NOTICE:

The vernier calipers must be in contact with the chain rollers when measuring.

Wrap the chain around the sprocket.

Using vernier calipers, measure the sprocket diameter with the chain wrapped around.

Minimum gear diameter (with chain):

97.3 mm (3.831 in.)

NOTICE:

The vernier calipers must be in contact with the chain rollers when measuring.

Wrap the chain around the timing sprocket.

Using vernier calipers, measure the timing gear diameter with the chain wrapped around.

Minimum gear diameter (with chain):

51.6 mm (2.031 in.)

NOTICE:

The vernier calipers must be in contact with the chain rollers when measuring.

Using vernier calipers, measure the tensioner slipper wear.

Maximum wear:

1.0 mm (0.039 in.)

Using vernier calipers, measure the vibration damper wear.

Maximum wear:

1.0 mm (0.039 in.)

Using vernier calipers, measure the vibration damper wear.

Maximum wear:

0.5 mm (0.020 in.)

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

Release the ratchet pawl, then check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.

Install the connecting rod cap (CAMRY_ACV40 RM000000YI700VX.html).

Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

Standard thrust clearance:

0.160 to 0.362 mm (0.0063 to 0.0143 in.)

Maximum thrust clearance:

0.362 mm (0.0143 in.)

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.

Check that the front mark of the connecting rod cap is facing forward.

Install the connecting rod cap (CAMRY_ACV40 RM000000YI700VX.html).

NOTICE:

Do not turn the crankshaft.

Remove the 2 bolts and connecting rod cap (CAMRY_ACV40 RM000000YI600VX.html).

Measure the Plastigage at its widest point.

Standard oil clearance:

0.032 to 0.063 mm (0.0013 to 0.0025 in.)

Maximum oil clearance:

0.063 mm (0.0025 in.)

NOTICE:

Completely remove the Plastigage after the measurement.

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, or 3 mark on its surface.

Standard connecting rod large end bore diameter:

Mark	Specified Condition
Mark 1	51.000 to 51.007 mm (2.0079 to 2.0082 in.)
Mark 2	51.008 to 51.013 mm (2.0082 to 2.0084 in.)
Mark 3	51.014 to 51.020 mm (2.0084 to 2.0087 in.)

Standard connecting rod bearing thickness:

Mark	Specified Condition
Mark 1	1.485 to 1.488 mm (0.0585 to 0.0586 in.)
Mark 2	1.489 to 1.491 mm (0.0586 to 0.0587 in.)
Mark 3	1.492 to 1.494 mm (0.0587 to 0.0588 in.)

Standard crankshaft pin diameter:

Mark	Specified Condition
Mark 1	47.990 to 48.000 (1.8894 to 1.8898 in.)
Mark 2	47.990 to 48.000 (1.8894 to 1.8898 in.)
Mark 3	47.990 to 48.000 (1.8894 to 1.8898 in.)

Using a precision straightedge and feeler gauge, measure the warpage of the surface that is in contact with the cylinder head gasket.

Maximum warpage:

0.05 mm (0.0020 in.)

Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.

Standard diameter:

88.500 to 88.513 mm (3.4843 to 3.4847 in.)

Maximum diameter:

88.633 mm (3.4894 in.)

Using a gasket scraper, remove the carbon from the piston top.

Using a groove cleaning tool or a broken ring, clean the piston ring grooves.

Using a brush and solvent, thoroughly clean the piston.

NOTICE:

Do not use a wire brush.

Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at the piston 44.3 mm (1.7441 in.) from the piston head.

Standard piston diameter:

88.469 to 88.479 mm (3.4830 to 3.4834 in.)

Subtract the piston diameter measurement from the cylinder bore diameter measurement.

Standard oil clearance:

0.021 to 0.044 mm (0.0008 to 0.0017 in.)

Maximum oil clearance:

0.10 mm (0.0039 in.)

Using a feeler gauge, measure the clearance between a new piston ring and wall of the ring groove.

Standard ring groove clearance:

Item	Specified Condition
No. 1 Ring	0.020 to 0.070 mm (0.0008 to 0.0028 in.)
No. 2 Ring	0.020 to 0.060 mm (0.0008 to 0.0024 in.)
Oil Ring	0.020 to 0.070 mm (0.0008 to 0.0028 in.)

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.

Using a feeler gauge, measure the end gap.

Standard end gap:

Item	Specified Condition
No. 1 Ring	0.24 to 0.31 mm (0.0094 to 0.0122 in.)
No. 2 Ring	0.33 to 0.43 mm (0.0130 to 0.0169 in.)
Oil Ring	0.10 to 0.30 mm (0.0040 to 0.0119 in.)

Maximum end gap:

Item	Specified Condition
No. 1 Ring	0.89 mm (0.0350 in.)
No. 2 Ring	1.37 mm (0.0539 in.)
Oil Ring	0.73 mm (0.0287 in.)

Using a caliper gauge, measure the piston pin bore diameter.

Standard piston pin bore diameter:

22.001 to 22.010 mm (0.8662 to 0.8665 in.)

Using a micrometer, measure the piston pin diameter.

Standard piston pin diameter:

21.997 to 22.006 mm (0.8660 to 0.8664 in.)

Using a caliper gauge, measure the connecting rod small end bore diameter.

Standard connecting rod small end bore diameter:

22.005 to 22.014 mm (0.8663 to 0.8667 in.)

Subtract the piston pin diameter measurement from the piston pin bore diameter measurement.

Standard oil clearance:

0.001 to 0.007 mm (0.00004 to 0.0003 in.)

Maximum oil clearance:

0.010 mm (0.0004 in.)

Subtract the piston pin diameter measurement from the connecting rod small end bore diameter measurement.

Standard oil clearance:

0.005 to 0.011 mm (0.0002 to 0.0004 in.)

Maximum oil clearance:

0.011 mm (0.0004 in.)

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.)

Using a connecting rod aligner and feeler gauge, check the connecting rod alignment.

1. Check for misalignment.
   

   Maximum misalignment:

   0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
   

   If the misalignment is greater than the maximum, replace the connecting rod.
   




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.
   

Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration.

Maximum circle runout:

0.03 mm (0.0012 in.)

Using a micrometer, measure the diameter of each main journal.

Standard diameter:

54.988 to 55.000 mm (2.1649 to 2.1654 in.)

Check each main journal for taper and distortion as shown in the illustration.

Maximum taper and distortion:

0.003 mm (0.0001 in.)

Standard diameter (Reference):

Mark	Specified Condition
0	54.999 to 55.000 mm (2.1653 to 2.1654 in.)
1	54.997 to 54.998 mm (2.1652 to 2.1653 in.)
2	54.995 to 54.996 mm (2.1652 to 2.1652 in.)
3	54.993 to 54.994 mm (2.1651 to 2.1651 in.)
4	54.991 to 54.992 mm (2.1650 to 2.1650 in.)
5	54.988 to 54.990 mm (2.1649 to 2.1650 in.)

Using a micrometer, measure the diameter of each crank pin.

Standard diameter:

47.990 to 48.000 mm (1.8894 to 1.8898 in.)

Inspect each crank pin for taper and distortion as shown in the illustration.

Maximum taper and distortion:

0.003 mm (0.0001 in.)

Install the main bearing cap (CAMRY_ACV40 RM000000YI700VX.html).

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 0.0095 in.)

Maximum thrust clearance:

0.30 mm (0.0118 in.)

HINT:

The thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.).

Check the crank journal and bearing for pitting and scratches.

Install the crankshaft bearing (CAMRY_ACV40 RM000000YI700VX.html).

Place the crankshaft on the cylinder block.

Lay a strip of Plastigage across each journal.

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 (CAMRY_ACV40 RM000000YI700VX.html).

NOTICE:

Do not turn the crankshaft.

Remove the main bearing caps (CAMRY_ACV40 RM000000YI600VX.html).

Measure the Plastigage at its widest point.

Standard oil clearance:

0.017 to 0.040 mm (0.0007 to 0.0016 in.)

Maximum oil clearance:

0.060 mm (0.0024 in.)

NOTICE:

Remove the Plastigage completely after the measurement.

HINT:

1. If replacing a bearing, select a new one with the same number. If the number of the bearing cannot be determined, calculate the correct bearing number by adding together the numbers imprinted on the cylinder block and crankshaft. Then select a new bearing with the calculated number. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.
   
2. EXAMPLE: Cylinder block "3" + Crankshaft "5" = Total number 8 (Use bearing "3")
   

Standard cylinder block journal bore diameter:

Mark	Specified Condition
0	59.000 to 59.002 mm (2.3228 to 2.3229 in.)
1	59.003 to 59.004 mm (2.3230 to 2.3230 in.)
2	59.005 to 59.006 mm (2.3230 to 2.3231 in.)
3	59.007 to 59.009 mm (2.3231 to 2.3232 in.)
4	59.010 to 59.011 mm (2.3232 to 2.3233 in.)
5	59.012 to 59.013 mm (2.3233 to 2.3234 in.)
6	59.014 to 59.016 mm (2.3234 to 2.3235 in.)

Standard crankshaft journal diameter:

Mark	Specified Condition
0	54.999 to 55.000 mm (2.1653 to 2.1654 in.)
1	54.997 to 54.998 mm (2.1652 to 2.1653 in.)
2	54.995 to 54.996 mm (2.1652 to 2.1652 in.)
3	54.993 to 54.994 mm (2.1651 to 2.1651 in.)
4	54.991 to 54.992 mm (2.1650 to 2.1650 in.)
5	54.988 to 54.990 mm (2.1649 to 2.1650 in.)

Standard bearing center wall thickness:

Mark	Specified Condition
1	1.993 to 1.996 mm (0.0785 to 0.0786 in.)
2	1.997 to 1.999 mm (0.0786 to 0.0787 in.)
3	2.000 to 2.002 mm (0.0787 to 0.0788 in.)
4	2.003 to 2.005 mm (0.0789 to 0.0789 in.)

Using vernier calipers, measure the tension portion diameter of the bolts.

Standard diameter:

7.3 to 7.5 mm (0.287 to 0.295 in.)

Minimum diameter:

7.2 mm (0.284 in.)