ENGINE UNIT(w/o DPF) INSPECTION

Click here Click here

PROCEDURE

1. Click here

   INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

   
   
   1. 

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

      Tip:

      If the roller does not turn smoothly, replace the valve rocker arm sub-assembly.

2. Click here

   INSPECT CHAIN SUB-ASSEMBLY

   
   
   1. 

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

      Maximum chain length
      156.5 mm (6.161 in.)

      Table 1. Text in Illustration

      *a	Measuring Area

      If the length is greater than the maximum, replace the chain.

      Tip:

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

3. Click here

   INSPECT NO. 2 CHAIN SUB-ASSEMBLY

   
   
   1. 

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

      Maximum chain length
      116.5 mm (4.586 in.)

      Table 2. Text in Illustration

      *a	Measuring Area

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

      Tip:

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

4. Click here

   INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

   
   
   1. 

      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.

5. Click here

   INSPECT CAMSHAFT TIMING SPROCKET

   
   

   1. Wrap the chain around the camshaft timing sprocket.

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

      Minimum sprocket diameter (with chain)
      132.5 mm (5.216 in.)

      Tip:

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

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

6. Click here

   INSPECT CRANKSHAFT TIMING SPROCKET

   
   

   1. Wrap the chain around the crankshaft timing sprocket.

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

      Minimum sprocket diameter (with chain)
      69.0 mm (2.716 in.)

      Tip:

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

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

7. Click here

   INSPECT OIL PUMP DRIVE GEAR

   
   

   1. Wrap the chain around the oil pump drive gear.

   2. Using a vernier caliper, measure the diameter of the oil pump drive gear including the wrapped chain.

      Minimum sprocket diameter (with chain)
      57.6 mm (2.267 in.)

      Tip:

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

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

8. Click here

   INSPECT OIL PUMP DRIVE SHAFT GEAR

   
   

   1. Wrap the chain around the oil pump drive shaft gear.

   2. Using a vernier caliper, measure the diameter of the oil pump drive shaft gear including the wrapped chain.

      Minimum sprocket diameter (with chain)
      53.5 mm (2.106 in.)

      Tip:

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

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

9. Click here

   INSPECT CHAIN TENSIONER SLIPPER

   
   

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

      Maximum wear
      1.0 mm (0.039 in.)

      Table 3. Text in Illustration

      *a

      Wear

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

10. Click here

    INSPECT NO. 1 CHAIN VIBRATION DAMPER

    
    

    1. Using a vernier caliper, measure the thickness of the chain vibration damper.

       Maximum wear
       1.0 mm (0.039 in.)

       Table 4. Text in Illustration

       *a

       Wear

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

11. Click here

    INSPECT CHAIN TENSIONER PLATE

    
    

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

       Maximum wear
       1.0 mm (0.039 in.)

       Table 5. Text in Illustration

       *a

       Wear

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

12. Click here

    INSPECT CAMSHAFT

    
    
    1. 

       Inspect the circle runout.

       
       

       1. Place the camshaft on V-blocks.

       2. 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. 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
          34.773 to 34.873 mm (1.3690 to 1.3730 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. Using a micrometer, measure the cam journal diameter.

          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 oil clearance.

13. Click here

    INSPECT CYLINDER HEAD SET BOLT

    
    
    1. 

       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.)

       Table 6. Text in Illustration

       *a	Measuring Point
       *b	55 mm (2.165 in.)

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