ENGINE UNIT INSPECTION

PROCEDURE


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


    1. A01ODMN

      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.

    • Only use clean engine oil.


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

      A01O9DRC21
      *a Correct *b Incorrect
      *c Taper *d Plunger
      *e Low Pressure Chamber *f Check Ball
      *g High Pressure Chamber - -

    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 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
      The plunger is very difficult to move.

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

  3. INSPECT CAMSHAFT


    1. Inspect the camshaft for runout.


      1. A01OAE3

        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.

        Click here

    2. Inspect the cam lobes (for intake valve).


      1. A01ODQP

        Using a micrometer, measure the cam lobe height.

        Standard Cam Lobe Height
        44.183 to 44.283 mm (1.73948 to 1.74342 in.)
        Minimum Cam Lobe Height
        44.073 mm (1.73515 in.)

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

        Tech Tips

        Check the camshaft oil clearance after replacing the camshaft.

        Click here

    3. Inspect the cam lobes (for fuel pump drive).


      1. A01OC3R

        Using a micrometer, measure the cam lobe height.

        Standard Cam Lobe Height
        40.554 to 40.654 mm (1.59661 to 1.60055 in.)
        Minimum Cam Lobe Height
        40.554 mm (1.59661 in.)

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

        Tech Tips

        Check the camshaft oil clearance after replacing the camshaft.

        Click here

    4. Inspect the camshaft journals.


      1. A01OCCE

        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 (0.904 to 0.905 in.)

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

        Click here

  4. INSPECT NO. 2 CAMSHAFT


    1. Inspect the No. 2 camshaft for runout.


      1. A01OD2X

        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.

        Click here

    2. Inspect the cam lobes.


      1. A01OC77

        Using a micrometer, measure the cam lobe height.

        Standard Cam Lobe Height
        43.533 to 43.633 mm (1.71389 to 1.71783 in.)
        Minimum Cam Lobe Height
        43.423 mm (1.70956 in.)

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

        Tech Tips

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

        Click here

    3. Inspect the camshaft journals.


      1. A01ODD4

        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 (0.904 to 0.905 in.)

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

        Click here

  5. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01ODAOC01
      *a Hexagonal Portion

      Using SST, secure the hexagonal portion of the camshaft, and then secure SST and the camshaft in a vise as shown in the illustration.

      SST
      09212-31010

      Note


      • Do not damage the camshaft.

      • Never grip areas other than the hexagonal portion as this may cause damage.

    2. A01OADKC27
      *a Lock Pin Released
      *b Lock Pin Locked
      *c Pin Hole
      *d Lock Check Point

      Check the camshaft timing gear assembly position.

      If the camshaft timing gear assembly is not set to the advanced position, release the lock pin and reset the camshaft timing gear assembly.

    3. A01O9A9C60
      *a Pin Hole
      *b Knock Pin

      Align and fit the knock pin of the camshaft to the pin hole of the camshaft timing gear assembly.

    4. A01O9C5C95
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Gap
      *d Camshaft Flange
      *e No Gap

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

    5. While securely holding the camshaft, install the 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.

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


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

    7. Release the lock pin.


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

      2. A01OCPDC02
        *a Retard Side Path
        *b Advance Side Path
        *c Open
        *d Close
        *e Knock Pin
        B004FOV Rubber Piece
        B004FVZ Vinyl Tape

        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 3 of the paths with pieces of rubber.

      3. Make a hole in the tape over port (A) shown in the illustration.

      4. A01OCL3

        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).

        Note


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

        • 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.

    8. Check for smooth rotation.


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

        Note


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

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

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

    10. Remove the bolt and camshaft timing gear assembly.

    11. A01OC6NC11
      *a Chain Roller

      Inspect the camshaft timing gear assembly.


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

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

        Minimum Diameter (with Chain Sub-assembly)
        115.12 mm (4.53 in.)

        Tech Tips

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

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

  6. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01ODAOC01
      *a Hexagonal Portion

      Using SST, secure the hexagonal portion of the No. 2 camshaft, and then secure SST and the No. 2 camshaft in a vise as shown in the illustration.

      SST
      09212-31010

      Note


      • Do not damage the No. 2 camshaft.

      • Never grip areas other than the hexagonal portion as this may cause damage.

    2. Install the camshaft timing exhaust gear assembly to the No. 2 camshaft.

      Click here

    3. Release the lock pin.


      1. Clean the No. 2 camshaft journal with non-residue solvent.

      2. A01OB2JC06
        *a Advance Side Path
        *b Retard Side Path
        *c Open
        *d Close
        *e Knock Pin
        B004FOV Rubber Piece
        B004FVZ Vinyl Tape

        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 over the 2 oil holes that are not plugged with rubber pieces.

      4. A01OCWWC10
        *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 oil paths with a piece of cloth when applying pressure to prevent oil from spraying.

      5. A01OCUXC10
        *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

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

      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

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

    4. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear assembly within its movable range (21.5 to 23.5°) 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.

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

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

    7. A01OBNDC13
      *a Chain Roller

      Inspect the camshaft timing exhaust gear assembly.


      1. Place the chain sub-assembly around the camshaft timing exhaust gear assembly.

      2. Using a vernier caliper, measure the camshaft timing exhaust gear assembly diameter with the chain sub-assembly.

        Minimum Diameter (with Chain Sub-assembly)
        115.12 mm (4.53 in.)

        Tech Tips

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

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

  7. INSPECT CHAIN SUB-ASSEMBLY


    1. A01OCQDC28
      *a Measurement Area

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

  8. INSPECT CRANKSHAFT TIMING SPROCKET


    1. A01O9A2C03
      *a Chain Roller

      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 when measuring.

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

  9. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01OBW6C04
      *a Plunger
      *b Stopper Plate

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

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

  10. INSPECT CHAIN TENSIONER SLIPPER


    1. A01OCM6C03
      *a Depth

      Using a vernier caliper, 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.

  11. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. A01OCNUC01
      *a Depth

      Using a vernier caliper, 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.

  12. INSPECT TIMING CHAIN GUIDE


    1. A01OAV1C01
      *a Depth

      Using a vernier caliper, 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.

  13. INSPECT BALANCE SHAFT THRUST CLEARANCE


    1. A01OBI4C03
      *a No. 1 Balance Shaft

      Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.

      Standard Thrust Clearance
      0.07 to 0.11 mm (0.00276 to 0.00433 in.)
      Maximum Thrust Clearance
      0.11 mm (0.00433 in.)

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

    2. A01OCD0C03
      *a No. 2 Balance Shaft

      Using a dial indicator, measure the thrust clearance while moving the No. 2 balance shaft back and forth.

      Standard Thrust Clearance
      0.07 to 0.11 mm (0.00276 to 0.00433 in.)
      Maximum Thrust Clearance
      0.11 mm (0.00433 in.)

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

  14. INSPECT BALANCE SHAFT BACKLASH


    1. A01ODLIC02
      *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 0.16 mm (0.00157 to 0.00630 in.)
      Maximum Backlash
      0.16 mm (0.00630 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.

  15. INSPECT CYLINDER HEAD SET BOLT


    1. A01OB8QC05
      *a Measurement Point
      *b 106 mm (4.17 in.)

      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. 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.

  16. INSPECT CAMSHAFT OIL CLEARANCE

    Note

    Do not turn the camshafts.


    1. Clean the camshaft bearing caps, camshaft housing sub-assembly and camshaft journals.

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

    3. A01OD3GC06
      *a Plastigage

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

    4. Install the camshaft bearing caps and camshaft housing sub-assembly.

      Click here

      Note


      • Do not apply engine oil to the camshaft bearing caps.


      • Do not turn the camshaft or No. 2 camshaft.

    5. Remove the camshaft bearing caps and camshaft housing sub-assembly.

      Click here

      Note

      Do not turn the camshaft or No. 2 camshaft.

    6. A01OC3WC06
      *a No. 1 Journal
      *b Other Journal
      *c Plastigage

      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 camshaft oil clearance is more than the maximum, replace the camshaft.

      If necessary, replace the camshaft housing sub-assembly.

  17. INSPECT CAMSHAFT THRUST CLEARANCE


    1. Clean the camshaft bearing caps, camshaft housing sub-assembly and camshaft journals.

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

    3. Install the camshaft bearing caps and camshaft housing sub-assembly.

      Click here

    4. A01OA9N

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

      Standard Thrust Clearance
      0.060 to 0.155 mm (0.00236 to 0.00610 in.)
      Maximum Thrust Clearance
      0.170 mm (0.00669 in.)

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

      If the thrust surface is damaged, replace the camshaft.