Lexus ES: 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 CAMSHAFT

(a) Inspect the camshaft for runout. (1) Place the camshaft 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 camshaft. Check the camshaft oil clearance after replacing the camshaft.

(b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard Cam Lobe Height: 42.217 to 42.417 mm (1.66208 to 1.66996 in.) Minimum Cam Lobe Height: 42.157 mm (1.65972 in.) HINT: If the cam lobe height is less than the minimum, replace the camshaft.

(c) Inspect the camshaft 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 (0.94327 to 0.94390 in.) HINT: If the journal diameter is not as specified, check the camshaft oil clearance. Click here

4. INSPECT NO. 2 CAMSHAFT

(a) Inspect the No. 2 camshaft for runout. (1) Place the No. 2 camshaft 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 No. 2 camshaft. Check the camshaft oil clearance after replacing the No. 2 camshaft.

(b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard Cam Lobe Height: Item Specified Condition No. 2 camshaft 37.914 to 38.114 mm (1.49267 to 1.50055 in.) No. 2 camshaft (for Fuel Pump) 39.398 to 39.598 mm (1.55110 to 1.55897 in.) Minimum Cam Lobe Height: Item Specified Condition No. 2 camshaft 37.804 mm (1.48834 in.) No. 2 camshaft (for Fuel Pump) 39.348 mm (1.54913 in.) HINT: If the cam lobe height is less than the minimum, replace the No. 2 camshaft.

(c) Inspect the No. 2 camshaft journals. (1) Using a micrometer, measure the journal diameter. Standard Journal Diameter: Item Specified Condition No. 1 journal 40.984 to 41.000 mm (1.61354 to 1.61417 in.) Other journals 23.959 to 23.975 mm (0.94327 to 0.94390 in.) HINT: If the journal diameter is not as specified, check the camshaft oil clearance. Click here

5. INSPECT CAMSHAFT OIL CLEARANCE

(a) Clean the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 2 No. 3 camshaft bearing caps, No. 4 camshaft bearing cap, camshaft housing sub-assembly and camshaft journals.

(b) Place the camshaft and No. 2 camshaft on the camshaft housing sub-assembly.

(c) Lay a strip of Plastigage across each of the camshaft journals.

*a Plastigage

(d) Install the camshaft bearing caps.

Click here

NOTICE:

Do not turn the camshafts.

(e) Remove the camshaft bearing caps.

Click here

(f) Measure the Plastigage at its widest point. Standard Oil Clearance (for Camshaft): 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.) Standard Oil Clearance (for No. 2 camshaft): Item Specified Condition No. 1 journal 0.027 to 0.064 mm (0.00106 to 0.00252 in.) Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.) Maximum Oil Clearance (for Camshaft): Item Specified Condition No. 1 journal 0.085 mm (0.00335 in.) Other journals 0.085 mm (0.00335 in.) Maximum Oil Clearance (for No. 2 camshaft): Item Specified Condition No. 1 journal 0.085 mm (0.00335 in.) Other journals 0.085 mm (0.00335 in.) NOTICE: Completely remove the Plastigage after the inspection. HINT: If the oil clearance is more than the maximum, replace the camshaft or No. 2 camshaft. If necessary, replace the camshaft housing sub-assembly.

*a Plastigage *b No. 1 Journal *c Other Journal

6. 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:

116.35 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.

7. INSPECT OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

(a) Using a spring scale, pull the oil pump drive 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:

116.35 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 oil pump drive chain sub-assembly.

8. INSPECT OIL PUMP DRIVE SPROCKET

(a) Place the oil pump drive chain sub-assembly around the oil pump drive sprocket.

(b) Using a vernier caliper, measure the diameter of the oil pump drive sprocket and oil pump drive chain sub-assembly.

Minimum Sprocket Diameter (with Oil Pump Drive Chain Sub-assembly):

51.23 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 oil pump drive chain sub-assembly and oil pump drive sprocket.

9. INSPECT OIL PUMP DRIVE SHAFT SPROCKET

(a) Place the oil pump drive chain sub-assembly around the oil pump drive shaft sprocket.

(b) Using a vernier caliper, measure the diameter of the oil pump drive shaft sprocket and oil pump drive chain sub-assembly.

Minimum Sprocket Diameter (with Oil Pump Drive Chain Sub-assembly):

51.23 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 oil pump drive chain sub-assembly and oil pump drive shaft sprocket.

10. 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):

100.01 mm (3.94 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.

11. 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):

100.01 mm (3.94 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.

12. 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):

51.23 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.

13. 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

14. 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

15. 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

16. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth. Standard Thrust Clearance: 0.05 to 0.09 mm (0.00197 to 0.00354 in.) Maximum Thrust Clearance: 0.09 mm (0.00354 in.) HINT: If the thrust clearance is more than the maximum, replace the engine balancer assembly.

17. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE

(a) Using a dial indicator, measure the thrust clearance while moving the No. 2 balance shaft back and forth. Standard Thrust Clearance: 0.05 to 0.09 mm (0.00197 to 0.00354 in.) Maximum Thrust Clearance: 0.09 mm (0.00354 in.) HINT: If the thrust clearance is more than the maximum, replace the engine balancer assembly.

18. 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 (4.13 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

(b) for 150 mm cylinder head set bolt:

(1) Using a vernier caliper, measure the diameter of the threads at the measurement point. Standard Diameter: 11.7 to 11.9 mm (0.461 to 0.469 in.) Minimum Diameter: 11.6 mm (0.457 in.) Measurement Point (Distance from the Seat): 115 mm (4.53 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

19. INSPECT EXHAUST MANIFOLD (TWC: Front Catalyst)

(a) Using a precision straightedge and feeler gauge, check the surface that contacts the cylinder head sub-assembly for warpage. Maximum Warpage: 0.7 mm (0.0276 in.) HINT: If the warpage is more than the maximum, replace the exhaust manifold (TWC: Front Catalyst).

20. INSPECT OIL NOZZLE VALVE SUB-ASSEMBLY

(a) Using a piece of wire, check that the check valve is not stuck.

*a	1 mm (0.0394 in.)
*b	5 mm (0.197 in.)
*c	Check Valve
*d	Wire
	Move the wire in this direction.
	Movement of Check Valve

(b) Connect a hose to the oil nozzle valve sub-assembly

*a Hose

(c) Check that air does not leak from the port (B) when blowing air into the port (A).

HINT:

If air leaks from the port (B), replace the oil nozzle valve sub-assembly with a new one.

(d) With the check valve depressed using a piece of wire, check that air flows from the port (B) when blowing air into the port (A).

*a	Hose
	Move the wire in this direction.
	Movement of Check Valve

HINT:

If air does not flow from the port (B), replace the oil nozzle valve sub-assembly with a new one.

(e) Disconnect the hose from the oil nozzle valve sub-assembly.

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