ENGINE UNIT INSPECTION


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


    1. A017CG8

      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 objects.

    • Only use clean engine oil.


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

    2. A017BTWE06

      Insert SST's tip into the valve lash adjuster assembly's plunger and use the tip to press down on the check ball inside the plunger.

      SST
      09276-75010

    3. Squeeze SST and 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 the air.

      OK
      Plunger moves up and down.

      Note

      When bleeding air from 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, air will not bleed.

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


    1. Inspect the camshaft for runout.


      1. Place the camshaft on V-blocks.

      2. A017F0T

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

        Maximum runout
        0.04 mm (0.0016 in.)

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

        Tech Tips

        Check the oil clearance after replacing the camshaft.

    2. A017FPY

      Using a micrometer, measure the cam lobe height.

      Standard cam lobe height
      Item Specification
      Intake camshaft 44.316 to 44.416 mm (1.7447 to 1.7487 in.)
      Exhaust camshaft 44.262 to 44.362 mm (1.7426 to 1.7465 in.)
      Maximum cam lobe height
      Item Specification
      Intake camshaft 44.166 mm (1.7388 in.)
      Exhaust camshaft 44.112 mm (1.7367 in.)
    3. A017G6S

      Using a micrometer, measure the journal diameter.

      Standard journal diameter
      Item Specification
      No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
      Other journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.)

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

  4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Clamp the camshaft in a vise.

      Note

      Be careful not to damage the camshaft in the vise.

    2. A017DANE02

      Put the camshaft timing gear assembly and camshaft together by aligning the key groove and straight pin.

    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, press harder after the pin enters the groove.

      Note

      Be sure not to turn the camshaft timing gear assembly in the retard direction.

    4. Check that there is no clearance between the camshaft timing gear assembly's flange and the camshaft.

    5. A017GBO

      Tighten the flange bolt with the camshaft timing gear assembly fixed.

      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

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


      1. Clamp the camshaft in a vise, and confirm that the camshaft timing gear assembly is locked.

        Note

        Be careful not to damage the camshaft.

    7. A017CPWE02

      Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        The 2 advance side paths are located in the camshaft grove. Plug one of the paths with a rubber piece.

      2. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration.

      3. A017DKKE03

        Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the 2 opened paths.

        CAUTION:

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

      4. A017CFZE02

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

        Tech Tips

        This operation releases the lock pin for the most retarded position.

      5. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure first from the retard side path and next from advance side path.

        Note

        Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

    8. Check for smooth rotation.


      1. Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.

        Note

        Do not use air pressure to perform the smooth operation check.

    9. Check the lock in the most retarded position.


      1. Confirm that the camshaft timing gear assembly locks at the most retarded position.

    10. A017F5AE03

      Remove the flange bolt and camshaft timing gear assembly.

      Note


      • Do not remove the other 3 bolts.

      • If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear.

  5. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Clamp the camshaft in a vise.

      Note

      Be careful not to damage the camshaft in the vise.

    2. A017DANE02

      Put the camshaft timing exhaust gear assembly and camshaft together by aligning the key groove and straight pin.

    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, press harder after the pin enters the groove.

      Note

      Be sure not to turn the camshaft timing exhaust gear in the retard direction.

    4. Check that there is no clearance between the gear's flange and the camshaft.

    5. A017FF7

      Tighten the flange bolt with the camshaft timing exhaust gear assembly fixed.

      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    6. Check the camshaft timing exhaust gear lock.


      1. Make sure that the camshaft timing exhaust gear assembly locks.

    7. A017DXBE03

      Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        The 2 advance side paths are located in the camshaft grove. Plug one of the paths with a rubber piece.

      2. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration.

      3. A017EEDE01

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

        CAUTION:

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

      4. A017EFGE02

        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 first 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.

    8. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear assembly turns smoothly.

        Note

        When the air pressure is released from the advance side path and then from the retard side path, the gear assembly 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.

    9. Check the lock at the most advanced position.


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

    10. A017FOAE02

      Remove the flange bolt and camshaft timing exhaust gear assembly.

      Note


      • Be sure not to remove the other 4 bolts.

      • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

  6. INSPECT CYLINDER HEAD SET BOLT


    1. A017EFLE03

      Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point.

      Standard outside diameter
      10.85 to 11.00 mm (0.4272 to 0.4331 in.)
      Minimum outside diameter
      10.70 mm (0.4213 in.)
      Measuring point
      103 mm (4.06 in.)

      Tech Tips

      If a visual check reveals no excessively thin areas, check the center of the bolt and find the area that has the lowest diameter.

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

  7. INSPECT CHAIN SUB-ASSEMBLY


    1. A017CIME01

      Pull the chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.

    2. Using vernier calipers, measure the length of 15 links.

      Maximum chain elongation
      136.9 mm (5.390 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.

  8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. A017CIME04

      Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.

    2. Using vernier calipers, measure the length of 15 links.

      Maximum chain elongation
      137.6 mm (5.417 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.

  9. INSPECT CRANKSHAFT TIMING SPROCKET


    1. Wrap the chain around the sprocket.

    2. A017CBM

      Using vernier calipers, measure the sprocket diameter with the chain sub-assembly.

      Minimum sprocket diameter (with chain)
      61.4 mm (2.417 in.)

      Tech Tips

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

      If the diameter is less than the minimum, replace the chain and sprocket.

  10. INSPECT IDLE SPROCKET ASSEMBLY


    1. Wrap the chain around the sprocket.

    2. A017G3E

      Using vernier calipers, measure the sprocket diameter with the chain.

      Minimum sprocket diameter (with chain)
      61.4 mm (2.417 in.)

      Tech Tips

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

      If the diameter is less than the minimum, replace the chain and sprocket.

  11. INSPECT IDLE GEAR SHAFT OIL CLEARANCE


    1. A017D4J

      Using a micrometer, measure the idle gear shaft diameter.

      Idle gear shaft diameter
      22.987 to 23.000 mm (0.9050 to 0.9055 in.)
    2. A017EUO

      Using a caliper gauge, measure the inside diameter of the idle sprocket assembly.

      Idle gear inside diameter
      23.020 to 23.030 mm (0.9063 to 0.9067 in.)

    3. Subtract the idle gear shaft diameter measurement from the idle sprocket inside diameter measurement.

      Standard oil clearance
      0.020 to 0.043 mm (0.0008 to 0.0017 in.)
      Maximum oil clearance
      0.093 mm (0.0037 in.)

      If the thrust oil clearance is greater than the maximum, replace the idle gear shaft and idle sprocket assembly.

  12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A017CUKE06

      Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly.

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

  13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A017EMPE01

      Check that the plunger moves smoothly.

    2. Measure the worn depth of the No. 2 chain tensioner assembly.

      Maximum depth
      0.9 mm (0.035 in.)

      If the depth is greater than the maximum, replace the No. 2 chain tensioner assembly.

  14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A017CSCE01

      Check that the plunger moves smoothly.

    2. Measure the worn depth of the No. 3 chain tensioner assembly.

      Maximum depth
      0.9 mm (0.035 in.)

      If the depth is greater than the maximum, replace the No. 3 chain tensioner assembly.

  15. INSPECT CHAIN TENSIONER SLIPPER


    1. A017D2BE01

      Measure the worn depth of the chain tensioner slipper.

      Maximum depth
      1.0 mm (0.039 in.)

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

  16. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. A017DQZE01

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

      Maximum depth
      1.0 mm (0.039 in.)

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

  17. INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. A017BVSE01

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

      Maximum depth
      1.0 mm (0.039 in.)

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

  18. INSPECT CAMSHAFT THRUST CLEARANCE


    1. Inspect the bank 1 camshaft thrust clearance.


      1. Install the bank 1 camshaft Click here.

      2. A017FYW

        Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

        Standard thrust clearance
        0.08 to 0.13 mm (0.0031 to 0.0051 in.)
        Maximum thrust clearance
        0.15 mm (0.006 in.)

        If the thrust clearance is greater than the maximum, replace the camshaft housing. If the thrust surface is damaged, replace the camshaft.

    2. Inspect the bank 2 camshaft thrust clearance.


      1. Install the bank 2 camshaft Click here.

      2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

        Standard thrust clearance
        0.08 to 0.13 mm (0.0031 to 0.0051 in.)
        Maximum thrust clearance
        0.15 mm (0.006 in.)

        If the thrust clearance is greater than the maximum, replace the camshaft housing. If the thrust surface is damaged, replace the camshaft.

  19. INSPECT CAMSHAFT OIL CLEARANCE


    1. Clean the camshaft bearing caps, camshaft housing and camshaft journals.

    2. Place the camshafts on the camshaft housing.

    3. A017G1AE01

      Lay a strip of Plastigage across each of the camshaft journals.

    4. Install the camshaft bearing caps Click here for Bank 1, Click here for Bank 2).

      Note

      Do not turn the camshaft.

    5. Remove the camshaft bearing caps Click here for Bank 1, Click here for Bank 2).

    6. A017F7OE03

      Measure the Plastigage at its widest point.

      Standard oil clearance
      Item Oil Clearance
      No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
      Other journals 0.025 to 0.062 mm (0.00098 to 0.0024 in.)
      Maximum oil clearance
      Item Oil Clearance
      No. 1 journal 0.10 mm (0.0039 in.)
      Other journals 0.09 mm (0.0035 in.)

      If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.

    7. Clean the camshaft bearing caps, camshaft housing and camshaft journals.

    8. Place the camshafts on the camshaft housing.

    9. A017FFGE01

      Lay a strip of Plastigage across each camshaft journal.

    10. Install the camshaft bearing caps Click here for Bank 1, Click here for Bank 2).

      Note

      Do not turn the camshaft.

    11. Remove the camshaft bearing caps Click here for Bank 1, Click here for Bank 2).

    12. A017DEPE03

      Measure the Plastigage at its widest point.

      Standard oil clearance
      Item Oil Clearance
      No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.)
      Other journals 0.025 to 0.062 mm (0.00098 to 0.0024 in.)
      Maximum oil clearance
      Item Oil Clearance
      No. 1 journal 0.10 mm (0.0039 in.)
      Other journals 0.09 mm (0.0035 in.)

      If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing sub-assembly.