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ENGINE UNIT INSPECTION

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PROCEDURE


  1. Click here

    INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. B004V22

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

      Tip:

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

  2. Click here

    INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Note:

    • Keep the valve lash adjuster assembly free of dirt and foreign objects.

    • Only use clean engine oil.


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

    2. B004S32C01
      *a CORRECT *b INCORRECT
      *c Tapered Path *d Plunger
      *e Low Pressure Chamber *f Check Ball
      *g High Pressure Chamber - -

      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.

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

      OK
      Plunger can be pressed 3 times.
      Tip:

      If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster with a new one.

  3. Click here

    INSPECT CAMSHAFT


    1. Inspect the camshaft runout.


      1. Place the camshaft on V-blocks.

      2. B004SZI

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

        Maximum circle runout
        0.04 mm (0.00157 in.)
        Tip:

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

        • Check the oil clearance after replacing the camshaft.

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    2. B004YFK

      Using a micrometer, measure the cam lobe height.

      Standard Cam Lobe Height
      Item Specified Condition
      Intake camshaft for Bank 1 44.335 to 44.435 mm (1.74547 to 1.74941 in.)
      for Bank 2 44.337 to 44.437 mm (1.74555 to 1.74948 in.)
      Exhaust camshaft for Bank 1 43.866 to 43.966 mm (1.72700 to 1.73094 in.)
      for Bank 2 43.867 to 43.967 mm (1.72704 to 1.73098 in.)
      for Fuel Pump 40.554 to 40.654 mm (1.59661 to 1.60055 in.)
      Minimum Cam Lobe Height
      Item Specified Condition
      Intake camshaft for Bank 1 44.235 mm (1.74153 in.)
      for Bank 2 44.237 mm (1.74161 in.)
      Exhaust camshaft for Bank 1 43.766 mm (1.72307 in.)
      for Bank 2 43.767 mm (1.72311 in.)
      for Fuel Pump 40.454 mm (1.59267 in.)
      Tip:

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

    3. B004TE6

      Using a micrometer, measure the journal diameter.

      Table 1. Standard Journal Diameter
      Item Specified
      No. 1 Journal 35.946 to 35.960 mm (1.41519 to 1.41575 in.)
      Other Journals 25.959 to 25.975 mm (1.02201 to 1.02264 in.)
      Tip:

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

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  4. Click here

    INSPECT CYLINDER HEAD SET BOLT


    1. B004UJ2C01
      *a Measurement Point
      *b 100 mm

      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
      10.70 mm (0.421 in.)
      Measurement Point (Distance from the Seat)
      100 mm (3.94 in.)
      Tip:

      • 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.

  5. Click here

    INSPECT CHAIN SUB-ASSEMBLY


    1. B004SBBC03
      *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 using a vernier caliper.

      Maximum chain elongation
      137.8 mm (5.43 in.)
      Tip:

      Perform the measurement at 3 random places. If a measurement is more than the maximum, replace the chain sub-assembly.

  6. Click here

    INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. B004SBBC06
      *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 using a vernier caliper.

      Maximum chain elongation
      137.8 mm (5.43 in.)
      Tip:

      Perform the measurement at 3 random places. If a measurement is more than the maximum, replace the No. 2 chain sub-assembly.

  7. Click here

    INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET


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

    2. B004XCQ

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

      Maximum Sprocket Diameter (with Chain Sub-assembly)
      62.2 mm (2.45 in.)
      Tip:

      • The vernier caliper must contact the chain rollers when measuring.

      • If the diameter is more than the maximum, replace the chain sub-assembly and crankshaft timing sprocket.

  8. Click here

    INSPECT IDLE SPROCKET ASSEMBLY


    1. Place the chain sub-assembly around the idle sprocket assembly.

    2. B004YMO

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

      Maximum Sprocket Diameter (with Chain Sub-assembly)
      65.2 mm (2.57 in.)
      Tip:

      • The vernier caliper must contact the chain rollers when measuring.

      • If the diameter is more than the maximum, replace the chain sub-assembly and idle sprocket assembly.

  9. Click here

    INSPECT NO. 1 IDLE GEAR SHAFT OIL CLEARANCE


    1. B004VHU

      Using a micrometer, measure the idle gear shaft diameter.

      Standard idle gear shaft diameter
      22.987 to 23.000 mm (0.905 to 0.906 in.)
    2. B004W87

      Using a caliper gauge, measure the inside diameter of the idle gear.

      Standard idle gear inside diameter
      23.020 to 23.030 mm (0.906 to 0.907 in.)

    3. Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement.

      Standard oil clearance
      0.020 to 0.043 mm (0.000787 to 0.00169 in.)
      Maximum oil clearance
      0.093 mm (0.00366 in.)
      Tip:

      If the oil clearance is more than the maximum, replace the No. 1 idle gear shaft and idle sprocket assembly.

  10. Click here

    INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B004YTLC01
      *a Plunger
      *b Stopper Plate

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

      Tip:

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

  11. Click here

    INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B004TS4C01
      *a Depth

      Check that the plunger moves smoothly.

    2. Using a vernier caliper, measure the wear depth of the No. 2 chain tensioner assembly.

      Maximum Depth
      1.0 mm (0.0394 in.)
      Tip:

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

  12. Click here

    INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B004VTWC01
      *a Depth

      Check that the plunger moves smoothly.

    2. Using a vernier caliper, measure the wear depth of the No. 3 chain tensioner assembly.

      Maximum Depth
      1.0 mm (0.0394 in.)
      Tip:

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

  13. Click here

    INSPECT CHAIN TENSIONER SLIPPER


    1. B004SQ6C01
      *a Depth

      Measure the depth of wear of the chain tensioner slipper.

      Maximum depth
      1.0 mm (0.0394 in.)
      Tip:

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

  14. Click here

    INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. B004WRHC01
      *a Depth

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

      Maximum depth
      1.0 mm (0.0394 in.)
      Tip:

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

  15. Click here

    INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. B004TB1C01
      *a Depth

      Using a vernier caliper, measure the wear depth of the No. 2 chain vibration damper.

      Maximum Depth
      1.0 mm (0.0394 in.)
      Tip:

      If the depth is more than the maximum, replace the No. 2 chain vibration damper.

  16. Click here

    INSPECT CAMSHAFT THRUST CLEARANCE


    1. Inspect the camshaft thrust clearance (for Bank 1).


      1. Install the camshaft.

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      2. Install the No. 2 camshaft.

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      3. B004V2D

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

        Standard Thrust Clearance
        0.08 to 0.130 mm (0.00315 to 0.00512 in.)
        Maximum Thrust Clearance
        0.18 mm (0.00709 in.)
        Tip:

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

        • If the thrust surface is damaged, replace the camshaft or No. 2 camshaft.

    2. Inspect the camshaft thrust clearance (for Bank 2).


      1. Install the No. 3 camshaft sub-assembly.

        Click here

      2. Install the No. 4 camshaft sub-assembly.

        Click here

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

        Standard Thrust Clearance
        0.08 to 0.130 mm (0.00315 to 0.00512 in.)
        Maximum Thrust Clearance
        0.18 mm (0.00709 in.)
        Tip:

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

        • If the thrust surface is damaged, replace the No. 3 camshaft sub-assembly or No. 4 camshaft sub-assembly.

  17. Click here

    INSPECT CAMSHAFT OIL CLEARANCE


    1. for Bank 1:


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

      2. Place the camshafts onto the camshaft housing sub-assembly.

      3. B004RCRC01
        *a Plastigage

        Lay a strip of Plastigage across each camshaft journal.

      4. Install the camshaft bearing caps.

        Click here

        Note:

        Do not turn the camshaft.

      5. Remove the camshaft bearing caps.

        Click here

      6. B004WWCC01
        *a Plastigage
        *b No. 1 Journal
        *c Other Journals

        Measure the Plastigage at its widest point.

        Standard Oil Clearance
        Item Specified Condition
        No. 1 journal 0.032 to 0.063 mm (0.00126 to 0.00248 in.)
        Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
        Maximum Oil Clearance
        Item Specified Condition
        No. 1 journal 0.1 mm (0.00394 in.)
        Other journals 0.1 mm (0.00394 in.)
        Tip:

        • If the oil clearance is more than the maximum, replace the camshaft or No. 2 camshaft.

        • If necessary, replace the camshaft housing sub-assembly.

    2. for Bank 2:


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

      2. Place the camshafts on the camshaft housing sub-assembly LH.

      3. B004TSWC01
        *a Plastigage

        Lay a strip of Plastigage across each camshaft journal.

      4. Install the camshaft bearing caps.

        Click here

        Note:

        Do not turn the camshaft.

      5. Remove the camshaft bearing caps.

        Click here

      6. B004VCXC01
        *a Plastigage
        *b No. 1 Journal
        *c Other Journals

        Measure the Plastigage at its widest point.

        Table 2. Standard Oil Clearance
        Item Specified Condition
        No. 1 Journal 0.032 to 0.063 mm (0.00126 to 0.00248 in.)
        Other Journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
        Table 3. Maximum Oil Clearance
        Item Specified Condition
        No. 1 Journal 0.1 mm (0.00394 in.)
        Other Journals 0.1 mm (0.00394 in.)
        Tip:

        • If the oil clearance is more than the maximum, replace the No. 3 camshaft sub-assembly or No. 4 camshaft sub-assembly.

        • If necessary, replace the camshaft housing sub-assembly LH.

  18. Click here

    INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY


    1. B004XT6

      Using a precision straightedge and feeler gauge, measure the warpage of the surface which contacts the cylinder head.

      Maximum warpage
      0.70 mm (0.0276 in.)
      Tip:

      If the warpage is more than the maximum, replace the exhaust manifold.

  19. Click here

    INSPECT INTAKE MANIFOLD


    1. B004X09C01
      *a Intake Air Surge Tank Side
      *b Cylinder Head Side

      Using a precision straightedge and feeler gauge, measure the warpage of the surfaces which contact the cylinder head and intake air surge tank.

      Maximum warpage
      0.1 mm (0.00394 in.)
      Tip:

      If the warpage is more than the maximum, replace the intake manifold.