ENGINE UNIT INSPECTION

PROCEDURE


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


    1. A01XQKK

      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 CAMSHAFT


    1. Inspect the camshaft for runout.


      1. Place the camshaft on V-blocks.

      2. A01XPTN

        Using a dial indicator, measure the runout at the center journal.

        Maximum Runout
        0.04 mm (0.00157 in.)

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

        Tech Tips

        Check the oil clearance after replacing the camshaft.

        Click here

    2. A01XQ22

      Using a micrometer, measure the cam lobe height.

      Standard Cam Lobe Height
      Item Specified Condition
      Intake 45.517 to 45.617 mm (1.79 to 1.80 in.)
      Exhaust 44.627 to 44.702 mm (1.76 to 1.76 in.)
      Minimum Cam Lobe Height
      Item Specified Condition
      Intake 44.903 mm (1.77 in.)
      Exhaust 44.526 mm (1.75 in.)

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

      Check the oil clearance after replacing the camshaft.

    3. A01XQ4U

      Using a micrometer, measure the journal diameter.

      Standard Journal Diameter
      Item Specified Condition
      No. 1 journal 29.956 to 29.970 mm (1.17937 to 1.17992 in.)
      Other journals 25.959 to 25.975 mm (1.02201 to 1.02264 in.)

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

      Click here

  3. INSPECT CAMSHAFT OIL CLEARANCE (for Bank 1)


    1. Clean the camshaft bearing caps, camshaft housing LH and camshaft journals.

    2. Place the camshafts on the camshaft housing LH.

    3. A01XRL3C02
      *a Plastigage

      Lay a strip of Plastigage across each camshaft journal.

    4. Install the camshaft bearing caps.

      Click here

      Note

      Do not turn the camshafts.

    5. Remove the camshaft bearing caps.

      Click here

    6. A01XR28C02
      *a No. 1 Journal
      *b Plastigage

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      Item Specified Condition
      No. 1 journal 0.030 to 0.069 mm (0.00118 to 0.00272 in.)
      Other journal 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
      Maximum Oil Clearance
      Item Specified Condition
      No. 1 journal 0.09 mm (0.00354 in.)
      Other journal 0.09 mm (0.00354 in.)

      If the oil clearance is more than the maximum, replace the camshaft and measure the oil clearance again.

      If the oil clearance is still more than the maximum even after replacing the camshaft with a new one, replace the cylinder head LH.

  4. INSPECT CAMSHAFT OIL CLEARANCE (for Bank 2)


    1. Clean the camshaft bearing caps, camshaft housing RH and camshaft journals.

    2. Place the camshafts on the camshaft housing RH.

    3. A01XRL3C02
      *a Plastigage

      Lay a strip of Plastigage across each camshaft journal.

    4. Install the camshaft bearing caps.

      Click here

      Note

      Do not turn the camshafts.

    5. Remove the camshaft bearing caps.

      Click here

    6. A01XR28C02
      *a No. 1 Journal
      *b Plastigage

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      Item Specified Condition
      No. 1 journal 0.030 to 0.069 mm (0.00118 to 0.00272 in.)
      Other journal 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
      Maximum Oil Clearance
      Item Specified Condition
      No. 1 journal 0.09 mm (0.00354 in.)
      Other journal 0.09 mm (0.00354 in.)

      If the oil clearance is more than the maximum, replace the camshaft and measure the oil clearance again.

      If the oil clearance is still more than the maximum even after replacing the camshaft with a new one, replace the cylinder head sub-assembly.

  5. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Note


    • Do not drop the camshaft timing gear assembly. If dropped, replace it.

    • Do not disassemble the camshaft timing gear assembly. If disassembled, replace it.


    1. A01XRK5C01
      *a Keyway

      Using a vernier caliper, measure the keyway of the camshaft timing gear assembly eccentric shaft cutout.

      Standard Width
      5.9 to 6.2 mm (0.232 to 0.244 in.)
      Maximum Width
      6.7 mm (0.264 in.)

      If the width is greater than the maximum, replace the camshaft timing gear assembly.

    2. Rotate the keyway of the camshaft timing gear assembly eccentric shaft by hand.

      Standard
      Rotates smoothly

      If the result is not as specified, replace the camshaft timing gear assembly.

  6. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


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


      1. Secure the camshaft in a vise between aluminum plates, and confirm that the camshaft timing exhaust gear assembly is locked.

        Note

        Do not overtighten the vise.

    2. A01XQHGC08
      *a Open
      *b Close
      *c Advanced Side Path
      *d Retard Side Path
      *e Vinyl Tape

      Release the lock pin.


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

      2. Make a hole in the tape on the advance side path and retard side path as shown in the illustration.

      3. A01XQ0CC05
        *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 the retard side path).

        Note

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

      4. A01XRLPC04
        *a Advance Side Path
        *b Retard Side Path
        *c Hold Pressure
        *d Decompress

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

        Tech Tips

        This operation releases the lock pin for the most retarded position.

      5. When the camshaft timing exhaust gear assembly reaches the most advanced position, release the air pressure from the retard side path, and then release the air pressure from the advance side path.

        Note

        Do not release the air pressure from the retard side path first. The camshaft timing exhaust gear may abruptly shift in the advance direction and break the lock pin.

    3. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.

        Note

        Do not use air pressure to perform the smooth operation check.

    4. Check the lock at the most advanced position.


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

  7. INSPECT CYLINDER HEAD SET BOLT


    1. A01XQ3PC01
      *a Measurement Point

      Using a vernier caliper, measure the diameter of the thread 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
      for Intake Side Bolt
      90 mm (3.54 in.)
      for Exhaust Side Bolt
      85 mm (3.35 in.)

      Note


      • If the diameter is less than the minimum, replace the cylinder head set bolt. 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.

  8. INSPECT CHAIN SUB-ASSEMBLY


    1. A01XRQ5C11
      *a Measurement Area

      Using a spring scale, pull the chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) and measure the length of the chain sub-assembly using a vernier caliper.

      Maximum Chain Elongation
      136.9 mm (5.39 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 NO. 2 CHAIN SUB-ASSEMBLY


    1. A01XRQ5C11
      *a Measurement Area

      Using a spring scale, pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) and measure the length of the No. 2 chain sub-assembly using a vernier caliper.

      Maximum Chain Elongation
      137.6 mm (5.42 in.)

      If the elongation is greater than the maximum, replace the No. 2 chain sub-assembly.

      Tech Tips

      Perform the measurement at 3 random places.

  10. INSPECT CRANKSHAFT TIMING GEAR


    1. Place the chain sub-assembly around the crankshaft timing gear.

    2. A01XRQW

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

      Minimum Sprocket Diameter (with Chain Sub-assembly)
      61.4 mm (2.42 in.)

      Tech Tips

      The vernier caliper must contact the chain rollers when measuring.

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

  11. INSPECT CRANKSHAFT TIMING SPROCKET LH


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

    2. A01XQDR

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

      Minimum Sprocket Diameter (with Chain Sub-assembly)
      61.4 mm (2.42 in.)

      Tech Tips

      The vernier caliper must contact the crankshaft timing sprocket LH when measuring.

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

  12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01XQX9C03
      *a Plunger
      *b Stopper Plate
      *c Moves Smoothly

      Turn the stopper plate clockwise 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.

  13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

    A01XRGBC03
    *a Depth
    *b Moves Smoothly

    1. Check that the plunger moves smoothly.

    2. Measure the depth of wear of the No. 2 chain tensioner assembly.

      Maximum Depth
      0.9 mm (0.0354 in.)

      If the depth is more than the maximum, replace the No. 2 chain tensioner assembly.

  14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY

    A01XRKMC02
    *a Depth
    *b Moves Smoothly

    1. Check that the plunger moves smoothly.

    2. Measure the depth of wear of the No. 3 chain tensioner assembly.

      Maximum Depth
      0.9 mm (0.0354 in.)

      If the depth is more than the maximum, replace the No. 3 chain tensioner assembly.

  15. INSPECT CHAIN TENSIONER SLIPPER


    1. A01XRPJC03
      *a Depth

      for Bank 1:


      1. Measure the depth of wear 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.

    2. A01XRCKC02
      *a Depth

      for Bank 2:


      1. Measure the depth of wear 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.

  16. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. A01XQVAC02
      *a Depth

      for Bank 1:


      1. Measure the depth of wear 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.

    2. A01XRI2C02
      *a Depth

      for Bank 2:


      1. Measure the depth of wear 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.

  17. INSPECT CYLINDER HEAD SUB-ASSEMBLY

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