Toyota Yaris: Engine Unit / Inspection

INSPECTION

PROCEDURE

1. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

(a) Turn the roller by hand to check that it turns smoothly. HINT: If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.

2. INSPECT VALVE LASH ADJUSTER ASSEMBLY

(a) Place the valve lash adjuster assembly into a container filled with engine oil.

(b) Insert the tip of SST into the valve lash adjuster assembly plunger and use the tip to press down on the check ball inside the plunger.

SST: 09276-75010

(c) Squeeze SST and the valve lash adjuster assembly together to move the plunger up and down 5 to 6 times.

(d) Check the movement of the plunger and bleed the air.

OK:

Plunger moves up and down.

NOTICE:

When bleeding air from the high-pressure chamber, make sure that the tip of SST is pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

(e) After bleeding the air, remove SST. Then try to quickly and firmly press the plunger by hand.

OK:

The plunger is very difficult to move.

HINT:

If the plunger is easy to move, replace the valve lash adjuster assembly.

3. INSPECT INTAKE CAMSHAFT SUB-ASSEMBLY

(a) Inspect the intake camshaft sub-assembly for runout. (1) Place the intake camshaft sub-assembly on V-blocks. (2) Using a dial indicator, measure the runout at the center journal. Maximum Runout: 0.03 mm (0.00118 in.) HINT: If the runout is more than the maximum, replace the intake camshaft sub-assembly. Check the intake camshaft sub-assembly oil clearance after replacing the intake camshaft sub-assembly.

(b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard Cam Lobe Height: 38.303 to 38.403 mm (1.508 to 1.512 in.) Minimum Cam Lobe Height: 38.302 mm (1.5079 in.) HINT: If the cam lobe height is less than the minimum, replace the intake camshaft sub-assembly.

(c) Inspect the intake camshaft sub-assembly journals. (1) Using a micrometer, measure the journal diameter. Standard Journal Diameter: Item Specified Condition No. 1 journal 33.984 to 34.000 mm (1.33795 to 1.33858 in.) Other journals 23.959 to 23.975 mm (0.94326 to 0.94389 in.)

4. INSPECT EXHAUST CAMSHAFT SUB-ASSEMBLY

(a) Inspect the exhaust camshaft sub-assembly for runout. (1) Place the exhaust camshaft sub-assembly on V-blocks. (2) Using a dial indicator, measure the runout at the center journal. Maximum Runout: 0.03 mm (0.00118 in.) HINT: If the runout is more than the maximum, replace the exhaust camshaft sub-assembly. Check the camshaft oil clearance after replacing the exhaust camshaft sub-assembly.

(b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard Cam Lobe Height: Item Specified Condition Exhaust camshaft sub-assembly 38.572 to 38.672 mm (1.519 to 1.523 in.) Exhaust camshaft sub-assembly (for Fuel Pump) 39.550 to 39.650 mm (1.557 to 1.561 in.) Minimum Cam Lobe Height: Item Specified Condition Exhaust camshaft sub-assembly 38.571 mm (1.5185 in.) Exhaust camshaft sub-assembly (for Fuel Pump) 39.549 mm (1.5570 in.) HINT: If the cam lobe height is less than the minimum, replace the exhaust camshaft sub-assembly.

(c) Inspect the exhaust camshaft sub-assembly journals. (1) Using a micrometer, measure the journal diameter. Standard Journal Diameter: Item Specified Condition No. 1 journal 40.967 to 40.983 mm (1.613 to 1.614 in.) Other journals 23.958 to 23.968 mm (0.943 to 0.944 in.)

5. INSPECT CHAIN SUB-ASSEMBLY

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

*a Measurement Length

(b) Using a vernier caliper, measure the length of 15 links.

Maximum Chain Elongation:

116.30 mm (4.58 in.)

NOTICE:

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

HINT:

If the average elongation is more than the maximum, replace the chain sub-assembly.

6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

(a) Place the chain sub-assembly around the camshaft timing gear assembly.

(b) Using a vernier caliper, measure the diameter of the camshaft timing gear assembly and chain sub-assembly.

Minimum Gear Diameter (with Chain Sub-assembly):

114.09 mm (4.49 in.)

NOTICE:

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

HINT:

If the diameter is less than the minimum, replace the chain sub-assembly and camshaft timing gear assembly.

7. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

(a) Place the chain sub-assembly around the camshaft timing exhaust gear assembly.

(b) Using a vernier caliper, measure the diameter of the camshaft timing exhaust gear assembly and chain sub-assembly.

Minimum Gear Diameter (with Chain Sub-assembly):

114.09 mm (4.49 in.)

NOTICE:

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

HINT:

If the diameter is less than the minimum, replace the chain sub-assembly and camshaft timing exhaust gear assembly.

8. INSPECT CRANKSHAFT TIMING SPROCKET

(a) Place the chain sub-assembly around the crankshaft timing sprocket.

(b) Using a vernier caliper, measure the diameter of the crankshaft timing sprocket and chain sub-assembly.

Minimum Sprocket Diameter (with Chain Sub-assembly):

51.35 mm (2.02 in.)

NOTICE:

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

HINT:

If the diameter is less than the minimum, replace the chain sub-assembly and crankshaft timing sprocket.

9. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Push the plunger and check that it moves smoothly. HINT: If the plunger does not move smoothly, replace the No. 1 chain tensioner assembly.

*a Plunger

10. INSPECT CHAIN TENSIONER SLIPPER

(a) Using a vernier caliper, measure the wear depth of the chain tensioner slipper. Maximum Depth: 1.0 mm (0.0394 in.) HINT: If the depth is more than the maximum, replace the chain tensioner slipper.

*a Depth

11. INSPECT NO. 1 CHAIN VIBRATION DAMPER

(a) Using a vernier caliper, measure the wear depth of the No. 1 chain vibration damper. Maximum Depth: 1.0 mm (0.0394 in.) HINT: If the depth is more than the maximum, replace the No. 1 chain vibration damper.

*a Depth

12. INSPECT CYLINDER HEAD SET BOLT

(a) for 140 mm cylinder head set bolt:

(1) Using a vernier caliper, measure the diameter of the threads at the measurement point. Standard Diameter: 10.7 to 10.9 mm (0.421 to 0.429 in.) Minimum Diameter: 10.6 mm (0.417 in.) Measurement Point (Distance from the Seat): 105 mm (4.134 in.) HINT: If the diameter is less than the minimum, replace the cylinder head set bolt with a new one. Failure to do so may lead to engine damage. If there is any thread deformation, replace the cylinder head set bolt with a new one.

*a Measurement Point *b 105 mm (4.134 in.)

(b) for 130 mm cylinder head set bolt:

(1) Using a vernier caliper, measure the diameter of the threads at the measurement point. Standard Diameter: 9.7 to 9.9 mm (0.382 to 0.390 in.) Minimum Diameter: 9.6 mm (0.378 in.) Measurement Point (Distance from the Seat): 115 mm (4.528 in.) HINT: If the diameter is less than the minimum, replace the cylinder head set bolt with a new one. Failure to do so may lead to engine damage. If there is any thread deformation, replace the cylinder head set bolt with a new one.

*a Measurement Point *b 115 mm (4.528 in.)