Engine Unit Inspection

Install the balanceshafts (COROLLA_ZRE142 RM00000224800UX.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 (COROLLA_ZRE142 RM00000224800UX.html).

NOTICE:

Do not turn the balanceshafts.

Remove the balanceshafts (COROLLA_ZRE142 RM00000224700UX.html).

Measure the Plastigage at its widest point.

Standard oil clearance:

0.022 to 0.049 mm (0.0009 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:

22.985 to 23.000 mm (0.9049 to 0.9055 in.)

Inspect the balanceshaft housing bolts.

1. Using a vernier caliper, 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 a vernier caliper, 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 a vernier caliper, 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 a vernier caliper, measure the sprocket diameter with the chain wrapped around.

Minimum gear diameter (with chain):

48.2 mm (1.898 in.)

NOTICE:

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

Wrap the chain around the sprocket.

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

Minimum gear diameter (with chain):

48.2 mm (1.898 in.)

NOTICE:

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

Wrap the chain around the sprocket.

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

Minimum gear diameter (with chain):

97.3 mm (3.831 in.)

NOTICE:

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

Wrap the chain around the sprocket.

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

Minimum gear diameter (with chain):

97.3 mm (3.831 in.)

NOTICE:

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

Wrap the chain around the timing sprocket.

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

Minimum gear diameter (with chain):

51.6 mm (2.031 in.)

NOTICE:

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

Using a vernier caliper, measure the tensioner slipper wear.

Maximum wear:

1.0 mm (0.039 in.)

Using a vernier caliper, measure the vibration damper wear.

Maximum wear:

1.0 mm (0.039 in.)

Using a vernier caliper, 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.

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:

   0.03 mm (0.0012 in.)
   

   If the circle runout is greater than the maximum, replace the camshaft.
   

Inspect the cam lobes.

1. Using a micrometer, measure the cam lobe heights.
   

   Standard cam lobe height:

   47.306 to 47.406 mm (1.8624 to 1.8664 in.)
   

   Minimum cam lobe height:

   47.196 mm (1.8581 in.)
   

   If any of the cam lobe heights are less than the minimum, replace the camshaft.
   

Inspect the camshaft journals.

1. Using a micrometer, measure the journal diameter.
   

   Standard Journal Diameter:

   Journal Position	Specified Condition
   No. 1	35.971 to 35.985 mm (1.4162 to 1.4167 in.)
   Others	22.959 to 22.975 mm (0.9039 to 0.9045 in.)

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

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:

   0.03 mm (0.0012 in.)
   

   If the circle runout is greater than the maximum, replace the No. 2 camshaft.
   

Inspect the cam lobes.

1. Using a micrometer, measure the cam lobe heights.
   

   Standard cam lobe height:

   46.063 to 46.163 mm (1.8135 to 1.8174 in.)
   

   Minimum cam lobe height:

   45.953 mm (1.8092 in.)
   

   If any of the cam lobe heights are less than the minimum, replace the No. 2 camshaft.
   

Inspect the camshaft journals.

1. Using a micrometer, measure the journal diameter.
   

   Standard Journal Diameter:

   Journal Position	Specified Condition
   No. 1	35.971 to 35.985 mm (1.4162 to 1.4167 in.)
   Others	22.959 to 22.975 mm (0.9039 to 0.9045 in.)

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