ENGINE UNIT INSPECTION

PROCEDURE


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


    1. A01W1QL

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

      Tech Tips

      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.

    • Only use clean engine oil.


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

      A01W2SDE04
      Text in Illustration
      *a Correct *b Incorrect
      *c Taper *d Low Pressure Chamber
      *e High Pressure Chamber *f Plunger
      *g Check Ball - -

    2. 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

    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, air will not bleed.

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

      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


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

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

    3. A01W34AE01
      Text in Illustration
      *a Plastigage

      Lay a strip of Plastigage across each of the camshaft journals.

    4. Install the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap Click here.

      Note

      Do not turn the camshafts.

    5. Install the camshaft housing sub-assembly Click here.

    6. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap Click here.

    7. A01W3J2E02
      Text in Illustration
      *a Plastigage
      *b No. 1 Journal
      *c Other Journal

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      Item Specified Condition
      Intake No. 1 journal 0.035 to 0.072 mm (0.00138 to 0.00283 in.)
      Exhaust No. 1 journal 0.049 to 0.086 mm (0.00193 to 0.00339 in.)
      Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
      Maximum Oil Clearance
      Item Specified Condition
      Intake No. 1 journal 0.085 mm (0.00335 in.)
      Exhaust No. 1 journal 0.095 mm (0.00374 in.)
      Other journals 0.085 mm (0.00335 in.)

      If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the camshaft housing sub-assembly.

  4. INSPECT CAMSHAFT THRUST CLEARANCE


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

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

    3. Install the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap Click here.

    4. Install the camshaft housing sub-assembly Click here.

    5. A01W5PD

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

      Standard Thrust Clearance
      Item Specified Condition
      Intake 0.060 to 0.155 mm (0.00236 to 0.00610 in.)
      Exhaust 0.060 to 0.155 mm (0.00236 to 0.00610 in.)
      Maximum Thrust Clearance
      Item Specified Condition
      Intake 0.170 mm (0.00669 in.)
      Exhaust 0.170 mm (0.00669 in.)

      If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly. If the thrust surface is damaged, replace the camshaft.

  5. INSPECT CAMSHAFT


    1. A01W4KL

      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.)

        If the runout is more than the maximum, replace the camshaft.

        Tech Tips

        Check the camshaft oil clearance after replacing the camshaft.

    2. A01VZUM

      Inspect the cam lobes (for intake valve).


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

        Standard Cam Lobe Height
        44.1823 to 44.2823 mm (1.73946 to 1.74339 in.)
        Minimum Cam Lobe Height
        44.0323 mm (1.73355 in.)

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

    3. A01W4NL

      Inspect the cam lobes (for fuel pump drive).


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

        Standard Cam Lobe Height
        42.1698 to 42.2698 mm (1.66023 to 1.66416 in.)
        Minimum Cam Lobe Height
        42.0198 mm (1.65432 in.)

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

    4. 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 (1.35626 to 1.35689 in.)
        Other journals 22.959 to 22.975 mm (0.90390 to 0.90453 in.)

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

  6. INSPECT NO. 2 CAMSHAFT


    1. A01W29R

      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.)

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

        Tech Tips

        Check the camshaft oil clearance after replacing the No. 2 camshaft.

    2. A01W0H8

      Inspect the cam lobes.


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

        Standard Cam Lobe Height
        43.5253 to 43.6253 mm (1.71359 to 1.71753 in.)
        Minimum Cam Lobe Height
        43.3753 mm (1.70769 in.)

        If the cam lobe height is less than the minimum, replace the No. 2 camshaft.

    3. 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 (1.35626 to 1.35689 in.)
        Other journals 22.959 to 22.975 mm (0.90390 to 0.90453 in.)

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

  7. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Install the camshaft timing exhaust gear assembly to the No. 2 camshaft Click here.

    2. A01VZ9XE02
      Text in Illustration
      *a Knock Pin
      *b Advance Side Path
      *c Retard Side Path
      *d Open
      *e Close
      B001O0C Rubber Piece
      B001NZR Vinyl Tape

      Release the lock pin.


      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. Make a hole in the vinyl tape placed on the advance side path. Make a hole in the vinyl tape placed on the retard side path on the opposite side to that of the advance side path as shown in the illustration.

      4. A01VZB8E01
        Text in Illustration
        *a Advance Side Path
        *b Retard Side Path

        Apply approximately 200 kPa (2.0 kgf/cm2, 29 psi) of air pressure to the 2 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. A01W1GXE02
        Text in Illustration
        *a Advance Side Path
        *b Retard Side Path
        *c Hold Pressure
        *d 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 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.

    3. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear assembly within its movable range (26.5 to 28.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the camshaft timing exhaust gear assembly turns smoothly.

        Note

        When the air pressure is released from the advance side path and then from the retard side path, the camshaft timing exhaust gear assembly 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.

    4. Check the lock at the most advanced position.


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

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

    6. Remove the bolt and camshaft timing exhaust gear assembly from the No. 2 camshaft.

  8. INSPECT CHAIN SUB-ASSEMBLY


    1. A01W1TUE12
      Text in Illustration
      *a Measurement Length

      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. Use the average of the measurements.

      If the average 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 Sub-assembly)
      59.94 mm (2.36 in.)

      Tech Tips

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

      If the diameter is less than the minimum, replace the crankshaft timing sprocket.

  10. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01W5AZE05
      Text in Illustration
      *a Plunger
      *b Stopper Plate

      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. A01W1CDE01
      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. A01W54GE01
      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. A01W0KYE01
      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. A01W1FBE03
      Text in Illustration
      *a Secure

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

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

  17. INSPECT CYLINDER HEAD SET BOLT


    1. A01W369E02
      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 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.

  18. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)


    1. A01W271

      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 (TWC: Front Catalyst).