ENGINE UNIT(w/ DPF) INSPECTION

PROCEDURE


  1. INSPECT OIL CHECK VALVE SUB-ASSEMBLY


    1. A01VEQIE03
      Text in Illustration
      *1 Ball
      A01VL3H Push

      Push the ball of the oil check valve sub-assembly to check if it is stuck.

      Note

      If the oil check valve sub-assembly is stuck, replace the oil check valve sub-assembly.

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


    1. A01VKGD

      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.

  3. INSPECT CHAIN SUB-ASSEMBLY


    1. A01VM92E01
      Text in Illustration
      *a Measuring Area

      Using a spring scale, apply 140 N (14.3 kgf, 31 lbf) to the chain sub-assembly then measure its length.

      Maximum chain sub-assembly length
      156.5 mm (6.161 in.)

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

      Tech Tips

      Measure the length in at least 3 places and calculate the average length.

  4. INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. A01VM92E01
      Text in Illustration
      *a Measuring Area

      Using a spring scale, apply 140 N (14.3 kgf, 31 lbf) to the No. 2 chain sub-assembly then measure its length.

      Maximum No. 2 chain sub-assembly length
      116.5 mm (4.586 in.)

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

      Tech Tips

      Measure the length in at least 3 places and calculate the average length.

  5. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01VI3T

      Check that the plunger moves smoothly when the cam is raised with your finger.

    2. Release the ratchet pawl and check that the plunger does not move when pushed with your finger.

      If necessary, replace the No. 1 chain tensioner assembly.

  6. INSPECT CAMSHAFT TIMING SPROCKET


    1. Wrap the chain sub-assembly around the camshaft timing sprocket.

    2. A01VDJ8

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

      Minimum camshaft timing sprocket diameter (with chain sub-assembly)
      133.8 mm (5.268 in.)

      If the diameter is less than the minimum, replace the camshaft timing sprocket.

      Tech Tips

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

  7. INSPECT CRANKSHAFT TIMING SPROCKET


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

    2. A01VISA

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

      Minimum crankshaft timing sprocket diameter (with chain sub-assembly)
      71.5 mm (2.815 in.)

      If the diameter is less than the minimum, replace the crankshaft timing sprocket.

      Tech Tips

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

  8. INSPECT OIL PUMP DRIVE GEAR


    1. Wrap the No. 2 chain sub-assembly around the oil pump drive gear.

    2. A01VKYL

      Using a vernier caliper, measure the diameter of the oil pump drive gear including the wrapped No. 2 chain sub-assembly.

      Minimum oil pump drive gear diameter (with No. 2 chain sub-assembly)
      56.4 mm (2.200 in.)

      If the diameter is less than the minimum, replace the oil pump drive gear.

      Tech Tips

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

  9. INSPECT OIL PUMP DRIVE SHAFT GEAR


    1. Wrap the No. 2 chain sub-assembly around the oil pump drive shaft gear.

    2. A01VKJM

      Using a vernier caliper, measure the diameter of the oil pump drive shaft gear including the wrapped No. 2 chain sub-assembly.

      Minimum oil pump drive shaft gear diameter (with No. 2 chain sub-assembly)
      58.6 mm (2.307 in.)

      If the diameter is less than the minimum, replace the oil pump drive shaft gear.

      Tech Tips

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

  10. INSPECT CHAIN TENSIONER SLIPPER


    1. A01VIBSE02
      Text in Illustration
      *a Wear

      Using a vernier caliper, measure the thickness of the chain tensioner slipper.

      Maximum wear
      1.0 mm (0.039 in.)

      If the thickness is greater than the maximum, replace the chain tensioner slipper.

  11. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. A01VK0CE02
      Text in Illustration
      *a Wear

      Using a vernier caliper, measure the thickness of the No. 1 chain vibration damper.

      Maximum wear
      1.0 mm (0.039 in.)

      If the thickness is greater than the maximum, replace the No. 1 chain vibration damper.

  12. INSPECT CHAIN TENSIONER PLATE


    1. A01VJAIE02
      Text in Illustration
      *a Wear

      Using a vernier caliper, measure the thickness of the chain tensioner plate.

      Maximum wear
      1.0 mm (0.039 in.)

      If the thickness is greater than the maximum, replace the chain tensioner plate.

  13. INSPECT CAMSHAFT


    1. Inspect the circle runout.


      1. Place the camshaft on V-blocks.

      2. A01VDSO

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

        Maximum circle runout
        0.03 mm (0.0012 in.)

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

    2. Inspect the height of the cam lobes.


      1. A01VFNN

        Using a micrometer, measure the cam lobe height.

        Standard cam lobe height
        34.484 to 34.584 mm (1.3576 to 1.3616 in.) for intake
        35.299 to 35.399 mm (1.3897 to 1.3937 in.) for exhaust
        Minimum cam lobe height
        34.064 mm (1.3411 in.) for intake
        34.353 mm (1.3525 in.) for exhaust

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

    3. Inspect the diameter of the cam journals.


      1. A01VKFS

        Using a micrometer, measure the cam journal diameter.

        Standard cam journal diameter
        23.979 to 23.995 mm (0.9441 to 0.9447 in.)

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

  14. INSPECT CYLINDER HEAD SET BOLT


    1. A01VHFVE05
      Text in Illustration
      *a Measuring Point
      *b 55 mm (2.165 in.)

      Using a vernier caliper, measure the minimum outer diameter of the compressed thread at the measuring point.

      Standard outer diameter
      11.5 to 12.0 mm (0.453 to 0.472 in.)
      Minimum outer diameter
      11.2 mm (0.441 in.)

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