ENGINE UNIT INSPECTION

PROCEDURE

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

   
   

   1. 

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

      Tech Tips

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

2. INSPECT CHAIN SUB-ASSEMBLY

   
   
   1. 

      Text in Illustration

      *a	Measuring Area

      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.)

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

      Tech Tips

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

3. INSPECT NO. 2 CHAIN SUB-ASSEMBLY

   
   
   1. 

      Text in Illustration

      *a	Measuring Area

      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.)

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

      Tech Tips

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

4. 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. 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.)

      Tech Tips

      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. 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.)

      Tech Tips

      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. 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.)

      Tech Tips

      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. 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.)

      Tech Tips

      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. INSPECT CHAIN TENSIONER SLIPPER

   

   Text in Illustration

   *a

   Wear

   
   

   1. 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.

10. INSPECT NO. 1 CHAIN VIBRATION DAMPER

    

    Text in Illustration

    *a

    Wear

    
    

    1. Using a vernier caliper, measure the thickness of the 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.

11. INSPECT CHAIN TENSIONER PLATE

    

    Text in Illustration

    *a

    Wear

    
    

    1. 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.

12. 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. INSPECT CYLINDER HEAD SET BOLT

    
    
    1. 

       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 bolt.