ENGINE UNIT INSPECTION

PROCEDURE


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


    1. A01W1Q0

      Turn the roller by hand to check that it turns smoothly.

      If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.

  2. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the valve lash adjuster assembly free from dirt and foreign matter.

    • Use only clean engine oil.

    A01W5OOE01
    Text in Illustration
    *1 Plunger
    *2 Check Ball
    *a CORRECT
    *b INCORRECT
    *c Taper Part
    *d Low Pressure Chamber
    *e High Pressure Chamber

    1. Place the valve lash adjuster assembly into a container full of new engine oil.

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

      SST
      09276-75010

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

    4. Check the movement of the plunger and bleed the air.

      OK
      Plunger moves up and down.

      Note

      When bleeding air from the high-pressure 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, the high-pressure chamber will not bled.

    5. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers.

      OK
      Plunger is very difficult to move.

      If the result is not as specified, replace the valve lash adjuster assembly.

  3. INSPECT CAMSHAFT OIL CLEARANCE

    Click here

  4. INSPECT CAMSHAFT THRUST CLEARANCE

    Click here

  5. INSPECT CAMSHAFT


    1. A01W2CD

      Inspect 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.

        Tech Tips

        Check the oil clearance after replacing the camshaft.

    2. A01W1FK

      Inspect the cam lobes.


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

        Standard Cam Lobe Height
        Item Specified Condition
        Intake 44.163 to 44.305 mm (1.739 to 1.744 in.)
        Exhaust 44.144 to 44.286 mm (1.738 to 1.744 in.)
        Minimum Cam Lobe Height
        Item Specified Condition
        Intake 44.013 mm (1.733 in.)
        Exhaust 43.996 mm (1.732 in.)

        If the cam lobe height is less than the minimum, replace the camshaft.

    3. A01W2IW

      Inspect the camshaft journals.


      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter
        Item Specified Condition
        No. 1 journal 34.449 to 34.465 mm (1.356 to 1.357 in.)
        Other journals 22.959 to 22.975 mm (0.904 to 0.905 in.)

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

  6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01W22RE04
      Text in Illustration
      *1 Knock Pin
      *a Pin Hole

      Align and insert the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

    2. A01VZE4E46
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

      Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.

    3. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear assembly by hand.

      Note

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    4. Check the lock of the camshaft timing gear assembly.


      1. Make sure that the camshaft timing gear assembly is locked.

        Note

        Be careful not to damage the camshaft.

    5. A01W3MAE03
      A01VZV9E03

      Release the lock pin.

      Text in Illustration
      *1 Rubber
      *2 Vinyl Tape
      *3 Knock Pin
      *a Retard Side Path
      *b Advance Side Path
      *c Open
      *d Close

      1. Clean the camshaft journal with non-residue solvent.

      2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        There are 4 oil paths in the grooves of the camshaft. Plug three of the paths with pieces of rubber.

      3. Open a hole at port A shown in the illustration.

      4. A01W3JU

        While applying approximately 200 kPa (2.0 kgf/ cm2, 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        CAUTION:

        Cover the paths with a piece of cloth when applying pressure to keep oil from spraying.

        Note

        Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

        Tech Tips


        • Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

    6. Check for smooth rotation.


      1. Turn the camshaft timing gear assembly within its movable range (19 to 21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.

        Note

        Do not allow the camshaft timing gear assembly to lock.

        If it locks, release the lock pin again.

    7. Remove the vinyl tape and rubber pieces from the camshaft.

    8. Remove the bolt and camshaft timing gear assembly.

  7. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01W0E5E06
      Text in Illustration
      *1 Knock Pin
      *a Pin Hole

      Align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

    2. A01VZE4E46
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

      Check that there is no clearance between the camshaft timing exhaust gear assembly and camshaft flange.

    3. Secure the No. 2 camshaft in place by hand, and then install the installation bolt of the camshaft timing exhaust gear assembly by hand.

    4. Check the lock of the camshaft timing exhaust gear assembly.


      1. Make sure that the camshaft timing exhaust gear assembly is locked.

        Note

        Be careful not to damage the No. 2 camshaft.

    5. A01W0HYE01
      A01W0F4E01

      Release the lock pin.

      Text in Illustration
      *1 Vinyl Tape
      *2 Rubber
      *3 Knock Pin
      *a Retard Side Path
      *b Advance Side Path
      *c Open
      *d Close

      1. Clean the camshaft journal with non-residue solvent.

      2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        There are 4 oil paths in the grooves of the No. 2 camshaft. Plug 2 paths with rubber pieces.

      3. Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path, as shown in the illustration.

      4. A01W47YE07
        Text in Illustration
        *1 Retard Side Path
        *2 Advance Side Path

        Apply approximately 200 kPa (2.0 kgf/cm2, 29 psi) of air pressure to the two open paths (the advance side path and retard side path).

        Note

        Cover the paths with a piece of cloth when applying pressure to keep oil from spraying.

      5. A01VZJZE06
        Text in Illustration
        *1 Retard Side Path
        *2 Advance Side Path
        *3 Hold Pressure
        *4 Decompress

        Check that the camshaft timing exhaust gear assembly turns in the retard direction when reducing the air pressure applied to the advance side path.

        Tech Tips

        The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.

      6. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path.

        Note

        Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.

    6. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear assembly within its movable range (19 to 21°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.

        Note

        When the air pressure is released from the advance side path and then from the retard side path, the gear automatically returns to the most advanced position due to the advance assist spring operation, and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

    7. Check the lock at the most advanced position.


      1. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position.

    8. Remove the vinyl tape and rubber pieces from the No. 2 camshaft.

    9. Remove the bolt and camshaft timing exhaust gear assembly.

  8. INSPECT CHAIN SUB-ASSEMBLY

    A01W1TUE11
    Text in Illustration
    *a Measurement Area

    1. 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.

    2. Using a vernier caliper, measure the length of 15 pins.

      Maximum chain elongation
      137.7 mm (5.42 in.)

      Tech Tips

      Perform the measurement at 3 random places.

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

  9. INSPECT CRANKSHAFT TIMING SPROCKET


    1. A01W3G1

      Place the chain sub-assembly around the crankshaft timing sprocket.

    2. Using a vernier caliper, measure the crankshaft timing sprocket diameter with the chain sub-assembly.

      Minimum sprocket diameter (with chain)
      59.94 mm (2.36 in.)

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

      Tech Tips

      The vernier caliper must contact the chain rollers for the measurement.

  10. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01W5AZ

      Move the stopper plate counterclockwise to release the lock. Push the plunger and check that it moves smoothly.

      If the plunger does not move smoothly, replace the No. 1 chain tensioner assembly.

  11. INSPECT CHAIN TENSIONER SLIPPER


    1. A01W4HHE05
      Text in Illustration
      *a Depth

      Measure the wear depth of the chain tensioner slipper.

      Maximum depth
      1.0 mm (0.0394 in.)

      If the depth is more than the maximum, replace the chain tensioner slipper.

  12. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. A01W3WME05
      Text in Illustration
      *a Depth

      Measure the wear depth of the No. 1 chain vibration damper.

      Maximum depth
      1.0 mm (0.0394 in.)

      If the depth is more than the maximum, replace the No. 1 chain vibration damper.

  13. INSPECT TIMING CHAIN GUIDE


    1. A01VZ60E08
      Text in Illustration
      *a Depth

      Measure the wear depth of the timing chain guide.

      Maximum depth
      1.0 mm (0.0394 in.)

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

  14. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE


    1. A01W44Y

      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.)

      If the thrust clearance is more than the maximum, replace the engine balancer assembly.

  15. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE


    1. A01W2MU

      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.)

      If the thrust clearance is more than the maximum, replace the engine balancer assembly.

  16. INSPECT BALANCE SHAFT BACKLASH


    1. A01W1FBE07
      Text in Illustration
      *a Fix

      Secure the No. 2 balance shaft in place, and then using a dial indicator, measure the backlash of the No. 1 and No. 2 balance shafts as shown in the illustration.

      Standard backlash
      0.04 to 0.17 mm (0.00157 to 0.00669 in.)
      Maximum backlash
      0.17 mm (0.00669 in.)

      Note

      Measure at 3 or more areas around the circumference of the No. 1 and No. 2 balance shafts.

      If the backlash is more than the maximum, replace the engine balancer assembly.

  17. INSPECT CYLINDER HEAD BOLT


    1. A01W56BE04
      Text in Illustration
      *a Measurement Point

      Using a vernier caliper, measure the diameter of the threads at the measurement point.

      Standard diameter
      10.85 to 11.00 mm (0.427 to 0.433 in.)
      Minimum diameter
      10.6 mm (0.417 in.)
      Measurement point (distance from the seat)
      106 mm (4.17 in.)

      Tech Tips


      • If the diameter is less than the minimum, replace the cylinder head bolt with a new one. Failure to do so may lead to engine damage.

      • If there is any thread deformation, replace the cylinder head bolt with a new one.

  18. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A01W3J5

      Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts the cylinder head sub-assembly.

      Maximum warpage
      0.7 mm (0.0276 in.)

      If the warpage is more than the maximum, replace the exhaust manifold converter sub-assembly.