ENGINE UNIT INSPECTION

PROCEDURE


  1. INSPECT CAMSHAFT TIMING SPROCKET ASSEMBLY


    1. Visually check the camshaft timing sprocket assembly.


      1. Visually check the camshaft timing sprocket assembly for wear or cracks.

        If the camshaft timing sprocket assembly is worn or cracked, replace the camshaft timing sprocket assembly.

    2. Install the camshaft timing sprocket assembly.


      1. Check that the straight pin is installed on the camshaft.

      2. Clamp the camshaft in a vise, and confirm that it is locked.

        Note


        • Do not overtighten the vise.

        • Do not damage the camshaft.

      3. A01VEAVE01
        Text in Illustration
        *a Straight Pin
        *b Straight Pin Hole

        Fit the camshaft timing sprocket assembly and camshaft together by aligning the straight pin hole and straight pin.

        Note


        • After insertion, gently rotate the camshaft timing sprocket assembly and check that the straight pin is securely inserted.

        • Because the tip of the camshaft straight pin may damage the seal surface of the camshaft timing sprocket assembly resulting in an improper seal, do not press forcefully on the camshaft timing sprocket assembly.

      4. Tighten the bolt with the camshaft timing sprocket assembly secured in place.

        Torque:
        47 N*m  { 479 kgf*cm, 35 ft.*lbf }

    3. Check the lock of the camshaft timing sprocket assembly.


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

    4. Release the lock pin.


      1. A01VKSIE02
        Text in Illustration
        *a Retard Side Path
        *b Advance Side Path
        *c Open
        *d Closed
        A01VEA4 Rubber Piece
        A01VHDF 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 2 of the paths with pieces of rubber.

      2. Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path, as shown in the illustration.

      3. A01VDRTE01
        Text in Illustration
        *a Advance Side Path
        *b Retard Side Path

        Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the 2 paths (the advance side path and the retard side path).

        Note

        Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.

      4. A01VKC3E01
        Text in Illustration
        *a Advance Side Path
        *b Retard Side Path
        A01VL3H Turn

        Check that the camshaft timing sprocket assembly turns in the advance direction when reducing the air pressure applied to the retard side path.

        Tech Tips

        The lock pin is released and the camshaft timing sprocket turns in the retard direction.

      5. When the camshaft timing sprocket moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure 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 sprocket may abruptly shift in the advance direction and break the lock pin or other parts.

    5. Check for smooth rotation.


      1. Turn the camshaft timing sprocket within its movable range (25°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the sprocket turns smoothly.

        Note

        Perform this check by hand, instead of using air pressure.

    6. Check the lock in the most retarded position.


      1. Confirm that the camshaft timing sprocket is locked in the most retarded position.

  2. INSPECT CHAIN SUB-ASSEMBLY


    1. Visually check the chain sub-assembly.


      1. A01VLXT

        Visually check the chain sub-assembly for wear or cracks.

        Note

        If the chain sub-assembly is worn or cracked, replace the chain sub-assembly and check the sprocket.

    2. Inspect the chain sub-assembly length.


      1. A01VHWQE20
        Text in Illustration
        *a Measurement Length

        Using a spring scale, pull the chain sub-assembly with a force of 225 N (23 kgf, 50.6 lbf) as shown in the illustration.

      2. Using a vernier caliper, measure the length of 15 links.

        Maximum chain elongation
        114.1 mm (4.49 in.)

        Note

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

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

  3. INSPECT CAMSHAFT TIMING SPROCKET ASSEMBLY


    1. Inspect camshaft timing sprocket assembly diameter.


      1. A01VJM3E02
        Text in Illustration
        *a Chain Roller

        Place the chain sub-assembly around the camshaft timing sprocket assembly.

      2. Using a vernier caliper, measure the diameter of the camshaft timing sprocket assembly and chain sub-assembly.

        Minimum gear diameter (with Chain)
        96.8 mm (3.811 in.)

        Note

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

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

  4. INSPECT CAMSHAFT TIMING GEAR


    1. Inspect camshaft timing gear diameter.


      1. A01VJYYE02
        Text in Illustration
        *a Chain Roller

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

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

      Minimum gear diameter (with Chain)
      96.8 mm (3.811 in.)

      Note

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

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

  5. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET


    1. Inspect crankshaft timing gear or sprocket diameter.


      1. A01VFMOE02
        Text in Illustration
        *a Chain Roller

        Place the chain sub-assembly around the crankshaft timing gear or sprocket.

      2. Using a vernier caliper, measure the diameter of the crankshaft timing gear or sprocket and chain sub-assembly.

        Minimum gear diameter (with Chain)
        51.1 mm (2.012 in.)

        Note

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

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

  6. INSPECT TIMING CHAIN TENSION ARM


    1. Inspect timing chain tension arm wear.


      1. A01VFUW

        Using a vernier caliper, measure the timing chain tension arm wear.

        Maximum wear
        0.5 mm (0.0197 in.)

        If the wear is greater than the maximum, replace the timing chain tension arm.

  7. INSPECT TIMING CHAIN GUIDE


    1. Inspect timing chain guide wear.


      1. A01VHJQ

        Using a vernier caliper, measure the timing chain guide wear.

        Maximum wear
        0.5 mm (0.0197 in.)

        If the wear is greater than the maximum, replace the timing chain guide.

  8. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. Inspect the No. 1 chain tensioner assembly operation.


      1. A01VH4VE02
        Text in Illustration
        *a Raise
        *b Move
        *c Lock

        Check that the plunger moves smoothly when the ratchet pawl is raised by hand.

      2. Release the ratchet pawl, then check that the plunger is locked in place by the ratchet pawl and does not move when pushed by hand.

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

  9. INSPECT CAMSHAFT


    1. Inspect the camshaft for runout.


      1. Place the camshaft on V-block.

      2. A01VK9C

        Using a dial indicator, measure the runout of the journal.

        Maximum runout
        0.03 mm (0.00118 in.)

        Tech Tips

        The runout is half of the value on the indicator when the camshaft is turned 1 revolution.

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

    2. Inspect the cam lobes.


      1. A01VKX8

        Using a micrometer, measure the cam lobe height.

        Standard cam lobe height
        41.409 to 41.509 mm (1.6303 to 1.6342 in.)
        Minimum cam lobe height
        41.399 mm (1.6299 in.)

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

    3. Inspect the camshaft journals.


      1. A01VGII

        Using a micrometer, measure the journal diameter.

        Standard Journal Diameter
        Journal Position Specification
        No. 1 33.974 to 33.990 mm (1.3376 to 1.3382 in.)
        Other 22.949 to 22.965 mm (0.9035 to 0.9041 in.)

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

  10. INSPECT NO. 2 CAMSHAFT


    1. Inspect the No. 2 camshaft for runout.


      1. Place the No. 2 camshaft on V-block.

      2. A01VH44

        Using a dial indicator, measure the runout of the journal.

        Maximum runout
        0.03 mm (0.00118 in.)

        Tech Tips

        The runout is half of the value on the indicator when the No. 2 camshaft is turned 1 revolution.

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

    2. Inspect the cam lobes.


      1. A01VHX9

        Using a micrometer, measure the cam lobe height.

        Standard cam lobe height
        40.972 to 41.072 mm (1.6131 to 1.6170 in.)
        Minimum cam lobe height
        40.872 mm (1.6091 in.)

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

    3. Inspect the No. 2 camshaft journals.


      1. A01VKR1

        Using a micrometer, measure the journal diameter.

        Standard Journal Diameter
        Journal Position Specification
        No. 1 25.979 to 25.995 mm (1.0228 to 1.0234 in.)
        Other 22.949 to 22.965 mm (0.9035 to 0.9041 in.)

        If the journal diameter is not as specified, check the No. 2 camshaft oil clearance Click here.

  11. INSPECT CYLINDER HEAD SET BOLT


    1. A01VGMGE02
      Text in Illustration
      *a Measurement Length

      Using a vernier caliper, measure the length of the cylinder head set bolt from the seat to the end.

      Standard bolt length
      121.0 to 122.0 mm (4.7638 to 4.8031 in.)
      Maximum bolt length
      123.5 mm (4.8622 in.)

      If the bolt length is greater than the maximum, replace the cylinder head set bolt.