ENGINE UNIT INSPECTION

PROCEDURE


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


    1. B004KHF

      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.

      B00715CC31
      *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 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.

      Tech Tips

      If the plunger is easy to move, replace the valve lash adjuster assembly.

  3. INSPECT CAMSHAFT


    1. B004MKO

      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.)

        Tech Tips


        • Check the camshaft oil clearance after replacing the camshaft.

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

    2. B004NF4

      Inspect the cam lobes.


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

        Standard Cam Lobe Height
        44.163 to 44.305 mm (1.73870 to 1.74429 in.)
        Minimum Cam Lobe Height
        44.013 mm (1.73279 in.)

        Tech Tips

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

    3. B004MWP

      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.)

        Tech Tips

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

        Click here

  4. INSPECT NO. 2 CAMSHAFT


    1. B004MKO

      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.)

        Tech Tips


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

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

    2. B004NF4

      Inspect the cam lobes.


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

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

        Standard Cam Lobe Height
        44.144 to 44.286 mm (1.73795 to 1.74354 in.)
        Minimum Cam Lobe Height
        43.996 mm (1.73212 in.)
    3. B004MWP

      Inspect the No. 2 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.)

        Tech Tips

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

        Click here

  5. INSPECT CAMSHAFT OIL CLEARANCE

    Note

    Do not turn the camshafts.


    1. Clean the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 3 No. 3 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. B006XH7C08
      *a Plastigage

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

    4. Install the camshaft bearing caps.

      Click here

    5. Install the camshaft housing sub-assembly.

      Click here

    6. Remove the camshaft bearing caps.

      Click here

    7. B006Z0CC08
      *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.)

      Tech Tips

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

  6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  7. INSPECT CHAIN SUB-ASSEMBLY


    1. B006X39C14
      *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 links.

      Maximum Chain Elongation
      137.7 mm (5.42 in.)

      Note

      Perform the measurement at 3 random places. Use the average of the measurements.

      Tech Tips

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

  8. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B006YYWC01
      *a Hexagonal Portion

      Using SST, grip the hexagonal portion, and then secure the SST and 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. B006Y76C36
      *a Knock Pin Hole
      *b Knock Pin

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

    3. B006XSRC47
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Gap
      *d No Gap

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

    4. While securely holding the No. 2 camshaft, install the bolt of the camshaft timing exhaust gear assembly by hand.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

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

    5. 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.

    6. Release the lock pin.

      B0070K3C14
      *a Retard Side Path *b Advance Side Path
      *c Open *d Closed
      *e Rubber Piece *f Vinyl Tape
      *g Knock 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 oil 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. B006Z5JC20
        *a Retard Side Path
        *b Advance 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 air pressure to prevent oil from spraying.

      5. B0070RPC20
        *a Retard Side Path
        *b Advance 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 and rotates the camshaft timing exhaust gear assembly rotates 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

        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.

    7. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear assembly within its movable range (19.0 to 21.0°) 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.

    8. Check the lock at the most advanced position.


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

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

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

  9. INSPECT CRANKSHAFT TIMING SPROCKET


    1. B004MZW

      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.)

      Note

      The vernier caliper must be in contact with the chain rollers when measuring.

      Tech Tips

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

  10. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B006ZDVC08
      *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, replace the No. 1 chain tensioner assembly.

  11. INSPECT CHAIN TENSIONER SLIPPER


    1. B00719NC08
      *a Depth

      Measure the wear depth of the chain tensioner slipper.

      Maximum Depth
      1.0 mm (0.0394 in.)

      Tech Tips

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

  12. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. B00715QC10
      *a Depth

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

      Maximum Depth
      1.0 mm (0.0394 in.)

      Tech Tips

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

  13. INSPECT TIMING CHAIN GUIDE


    1. B006X4AC10
      *a Depth

      Measure the wear depth of the timing chain guide.

      Maximum Depth
      1.0 mm (0.0394 in.)

      Tech Tips

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

  14. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE


    1. B004OCE

      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.)

      Tech Tips

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

  15. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE


    1. B004HDB

      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.)

      Tech Tips

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

  16. INSPECT BALANCE SHAFT BACKLASH


    1. B00713XC08
      *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.

      Tech Tips

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

  17. INSPECT CYLINDER HEAD SET BOLT


    1. B0071G2C11
      *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 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. B004JIV

      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.)

      Tech Tips

      If the warpage is more than the maximum, replace the exhaust manifold converter sub-assembly (TWC: Front Catalyst).