ENGINE UNIT INSPECTION

PROCEDURE


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


    1. B0045S0

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

      Tech Tips

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

  2. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Note


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

    • Only use clean engine oil.


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

    2. B00480RC06
      *a Correct
      *b Incorrect
      *c Taper
      *d Low Pressure Chamber
      *e High Pressure Chamber
      *f Plunger
      *g Check Ball

      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.

      SST
      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 it.

      OK
      Plunger moves up and down.

      Note

      When bleeding 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, the high-pressure chamber will not be bled.

    5. After bleeding, remove SST. Then try to quickly and firmly press the plunger by hand.

      OK
      Plunger is very difficult to move.

      If the result is not as specified, replace the valve lash adjuster assembly.

  3. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Install the camshaft timing gear assembly.

      Click here

    2. Check the lock of the camshaft timing gear assembly.


      1. Confirm that the camshaft timing gear assembly is locked.

    3. B0046EZC04
      *a Open
      *b Close
      *c Advance Side Path
      *d Retard Side Path
      *e Vinyl Tape
      *f Rubber

      Release the lock pin.


      1. 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 groove of the camshaft. Plug 3 of the paths with rubber pieces.

      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. B0047P5

        While applying approximately 150 kPa (1.5 kgf/cm2, 22 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        CAUTION:

        Cover the path with a piece of cloth when applying pressure to keep oil from spraying.

        Note

        Do not lock the camshaft timing gear assembly. If it is locked, release the lock pin again.

        Tech Tips


        • The camshaft timing gear assembly may be turned in the advance direction without applying any force.

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

    4. Check for smooth rotation.


      1. Turn the camshaft timing gear assembly within its movable range (20.5 to 22.5°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.

        Note

        Do not lock the camshaft timing gear assembly. If it is locked, release the lock pin again.

  4. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Install the camshaft timing exhaust gear assembly.

      Click here

    2. Check the lock of the camshaft timing exhaust gear assembly.


      1. Make sure that the camshaft timing exhaust gear assembly is locked.

    3. B0046EZC01
      *a Open
      *b Close
      *c Advance Side Path
      *d Retard Side Path
      *e Vinyl Tape
      *f Rubber

      Release the lock pin.


      1. 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 groove of the camshaft. Plug 2 of the paths with rubber pieces.

      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. B0047LNC01
        *a Advance Side Path
        *b Retard Side Path

        Apply approximately 200 kPa (2.0 kgf/cm2, 29 psi) of air pressure to the 2 open paths (the advance side path and the retard side path).

        CAUTION:

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

      4. B0047TJC01
        *a Decompress
        *b Hold Pressure
        *c Advance Side Path
        *d Retard Side Path

        Make sure that the camshaft timing exhaust gear assembly turns in the retard direction when reducing the air pressure applied to the advance side path.

        Tech Tips

        The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.

      5. When the camshaft timing exhaust gear assembly 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 exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.

    4. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear assembly within its movable range (24 to 26°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.

        Note

        When the air pressure is released from the advance side path and then from the retard side path, the gear automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

    5. Check the lock at the most advanced position.


      1. Make sure that the camshaft timing exhaust gear assembly is locked at the most advanced position.

  5. INSPECT CHAIN SUB-ASSEMBLY


    1. B0047FVC27
      *a Measurement Length

      Using a spring scale, pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.

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

      Maximum Chain Elongation
      115.2 mm (4.54 in.)

      Note

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

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

  6. INSPECT NO.2 CHAIN SUB-ASSEMBLY


    1. B0047FVC28
      *a Measurement Length

      Using a spring scale, pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.

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

      Maximum Chain Elongation
      102.1 mm (4.02 in.)

      Note

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

      If the average elongation is more than the maximum, replace the No. 2 chain sub-assembly.

  7. INSPECT OIL PUMP DRIVE GEAR


    1. B0047HF

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

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

      Minimum Gear Diameter (with No. 2 Chain Sub-assembly)
      48.2 mm (1.90 in.)

      Note

      The vernier caliper must be contact the chain rollers for the measurement.

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

  8. INSPECT OIL PUMP DRIVE SHAFT GEAR


    1. B0047DL

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

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

      Minimum Gear Diameter (with No. 2 Chain Sub-assembly)
      48.2 mm (1.90 in.)

      Note

      The vernier caliper must contact the chain rollers for the measurement.

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

  9. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. B0045RG

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

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

      Minimum Gear Diameter (with Chain Sub-assembly)
      96.8 mm (3.81 in.)

      Note

      The vernier caliper must contact the chain rollers for the measurement.

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

  10. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B00465N

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

    2. Using a vernier caliper, measure the camshaft timing exhaust gear assembly with the chain sub-assembly.

      Minimum Gear Diameter (with Chain Sub-assembly)
      96.8 mm (3.81 in.)

      Note

      The vernier caliper must contact the chain rollers for the measurement.

      If the diameter is less than the minimum, replace the camshaft timing exhaust gear assembly.

  11. INSPECT CRANKSHAFT TIMING SPROCKET


    1. B0047HF

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

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

      Minimum Gear Diameter (with Chain Sub-assembly)
      51.1 mm (2.01 in.)

      Note

      The vernier caliper must contact the chain rollers for the measurement.

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

  12. INSPECT CHAIN TENSIONER SLIPPER


    1. B0047R0

      Measure the wear depth of the chain tensioner slipper.

      Maximum Depth
      1.0 mm (0.0394 in.)

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

  13. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. B0046W9

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

      Maximum Depth
      1.0 mm (0.0394 in.)

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

  14. INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. B004601

      Measure the wear depth of the No. 2 chain vibration damper.

      Maximum Depth
      1.0 mm (0.0394 in.)

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

  15. INSPECT CHAIN TENSIONER PLATE


    1. B0046F0

      Measure the wear depth of the chain tensioner plate.

      Maximum Depth
      1.0 mm (0.0394 in.)

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

  16. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B0047CEC01
      *a Raise
      *b Move
      *c Lock

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

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

  17. INSPECT CAMSHAFT


    1. B00488U

      Inspect the camshaft for runout.


      1. Place the camshaft on V-blocks.

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

        Maximum Runout
        0.04 mm (0.00157 in.)

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

    2. B00480D

      Inspect the cam lobes.


      1. Using a micrometer, measure the cam lobe height.

        Standard Cam Lobe Height
        42.816 to 42.916 mm (1.68567 to 1.68960 in.)
        Minimum Cam Lobe Height
        42.666 mm (1.67976 in.)

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

    3. B0047Z1

      Inspect the camshaft journals.


      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter
        Item Specified Condition
        No. 1 journal 34.449 to 34.465 mm (1.35626 to 1.35689 in.)
        Other journals 22.949 to 22.965 mm (0.90350 to 0.90413 in.)

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

        Click here

  18. INSPECT NO.2 CAMSHAFT


    1. B00488U

      Inspect the No. 2 camshaft for runout.


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

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

        Maximum Runout
        0.04 mm (0.00157 in.)

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

    2. B00480D

      Inspect the cam lobes.


      1. Using a micrometer, measure the cam lobe height.

        Standard Cam Lobe Height
        44.336 to 44.436 mm (1.74551 to 1.74945 in.)
        Minimum cam lobe height
        44.186 mm (1.73960 in.)

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

    3. B0047Z1

      Inspect the camshaft journals.


      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter
        Item Specified Condition
        No. 1 journal 34.449 to 34.465 mm (1.35626 to 1.35689 in.)
        Other journals 22.949 to 22.965 mm (0.90350 to 0.90413 in.)

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

        Click here

  19. INSPECT CYLINDER HEAD SET BOLT


    1. B0045AIC17
      *a Measurement Length
      *b Measuring Area
      *c 115 mm (4.53 in.)

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

      Standard Length
      146.8 to 148.2 mm (5.78 to 5.83 in.)
      Maximum Length
      149.2 mm (5.87 in.)

      Tech Tips


      • If the diameter is less than the maximum, replace the cylinder head set bolt with a new one. 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.

    2. Using a vernier caliper, measure the diameter of the threaded at the several points.

      Tech Tips

      Use a straightedge to determine the thinnest point of the threaded portion of the bolt.

      Standard Diameter
      9.77 to 9.96 mm (0.385 to 0.392 in.)
      Minimum Diameter
      9.4 mm (0.370 in.)

      Tech Tips


      • If the diameter is less than the minimum, replace the cylinder head set bolt with a new one. 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.

  20. INSPECT EXHAUST MANIFOLD


    1. B0047DY

      Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head sub-assembly.

      Maximum Warpage
      0.7 mm (0.0276 in.)

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