ENGINE UNIT INSPECTION

PROCEDURE


  1. INSPECT CYLINDER HEAD SET BOLT


    1. B001XALE18
      Text in Illustration
      *1 Measuring Point

      Using a vernier caliper, measure the diameter of the elongated thread at the measuring point.

      Measuring point
      94 mm (3.70 in.) for intake side bolt
      89 mm (3.50 in.) for exhaust side bolt
      Standard diameter
      10.85 to 11.00 mm (0.427 to 0.433 in.)
      Minimum diameter
      10.6 mm (0.417 in.)

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

      Tech Tips

      If a visual check reveals no excessively thin areas, check the center of the bolt (see illustration) and find the area that has the smallest diameter.

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


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

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

  3. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the adjuster free from dirt and foreign objects.

    • Use only clean engine oil.

    B001WAWE01

    1. Place the lash adjuster into a container full of new engine oil.

    2. Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

      SST
      09276-75010

    3. Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times.

    4. Check the movement of the plunger and bleed air.

      OK
      Plunger moves up and down.
      Text in Illustration
      *1 Taper Part
      *2 Plunger
      *3 Low Pressure Chamber
      *4 Check Ball
      *5 High Pressure Chamber
      *a CORRECT
      *b INCORRECT

      Note

      When bleeding high-pressure air from the compression 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 your fingers.

      OK
      Plunger can be pressed 3 times.

      If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster with a new one.

  4. INSPECT CAMSHAFT SUB-ASSEMBLY


    1. Inspect the camshaft for runout.


      1. Place the camshaft on V-blocks.

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

        Maximum circle runout
        0.04 mm (0.00157 in.)

        If the circle runout is more than the maximum, replace the camshaft sub-assembly.

        Tech Tips

        Check the oil clearance after replacing the camshaft.

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

      Standard Cam Lobe Height
      Item Specified Condition
      Intake 44.291 to 44.441 mm (1.744 to 1.750 in.)
      Exhaust 44.196 to 44.346 mm (1.740 to 1.746 in.)
      Minimum Cam Lobe Height
      Item Specified Condition
      Intake 44.241 mm (1.742 in.)
      Exhaust 44.146 mm (1.738 in.)

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

    3. Using a micrometer, measure the journal diameter.

      Standard Journal Diameter
      Item Specified Condition
      No. 1 journal 29.956 to 29.970 mm (1.179 to 1.180 in.)
      Other journals 25.959 to 25.975 mm (1.022 to 1.023 in.)

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

  5. INSPECT CAMSHAFT OIL CLEARANCE


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

    2. Place the camshafts on the camshaft housing.

    3. B001Y9XE06
      Text in Illustration
      *1 Plastigage

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

    4. Install the camshaft bearing caps Click here.

      Note

      Do not turn the camshaft.

    5. Install the camshaft housing Click here.

      Note

      Do not turn the camshaft.

    6. Remove the camshaft bearing caps Click here.

    7. B001YHSE04
      Text in Illustration
      *1 Plastigage
      *2 No. 1 Journal
      *3 Other Journals

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      Item Specified Condition
      No. 1 journal 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
      Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
      Maximum Oil Clearance
      Item Specified Condition
      No. 1 journal 0.10 mm (0.00394 in.)
      Other journals 0.09 mm (0.00354 in.)

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

  6. INSPECT CAMSHAFT TIMING GEAR


    1. Install the camshaft bearing caps Click here.

      Tech Tips

      Only install the intake camshaft.

    2. Install the camshaft housing Click here.

    3. Apply a light coat of engine oil to the camshaft and camshaft timing gear.

    4. B001Z5JE14

      Using the hexagonal portion of the camshaft, align and attach the knock pin of the camshaft with the pin hole of the camshaft timing gear.

      Text in Illustration
      *1 Knock Pin
      *2 Key Groove

      Note


      • Do not forcefully push on the camshaft timing gear. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing gear.

      • B001VVJE22

        Do not loosen or remove the 3 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the camshaft timing gear assembly with a new one.

      Text in Illustration
      *1 Flange Bolt
      *2 Knock Pin
      *a Do not remove

    5. Apply a light coat of engine oil to the threads and under the head of the bolt.

    6. B001XVLE02
      Text in Illustration
      *a Hold
      B001XPG Turn

      Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing gear with the bolt.

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

    7. Remove the camshaft bearing caps Click here.

    8. Check the lock of the camshaft timing gear.


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

        Note

        Be careful not to damage the camshaft.

    9. B001VMGE12
      Text in Illustration
      *1 Advance Side Path
      *2 Retard Side Path
      *3 Open
      *4 Close
      B001YD9 Vinyl Tape

      Release the lock pin.


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

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

      3. B001Z9XE04
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path

        Apply approximately 200 kPa (2.0 kgf/cm2, 29 psi) of air pressure to the two broken paths.

        Note

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

      4. B001WVLE08
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *3 Decompress
        *4 Hold Pressure

        Check that the camshaft timing gear revolves 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 reaches the most advanced position, release the air pressure from the retard side path and advance side path, in that order.

        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.

    10. Check for smooth rotation.


      1. Turn the camshaft timing gear 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 rotation check.

    11. Check the lock in the most retarded position.


      1. Confirm that the camshaft timing gear is locked at the most retarded position.

    12. Install the camshaft bearing caps Click here.

      Tech Tips

      Only install the intake camshaft.

    13. Install the camshaft housing Click here.

    14. B001VWBE02
      Text in Illustration
      *a Hold
      B001XPG Turn

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

    15. Remove the camshaft bearing caps Click here.

    16. B001VVJE11
      Text in Illustration
      *1 Flange Bolt
      *2 Knock Pin
      *a Do not remove

      Remove the flange bolt and camshaft timing gear.

  7. INSPECT CAMSHAFT TIMING EXHAUST GEAR


    1. Install the camshaft bearing caps Click here.

      Tech Tips

      Only install the exhaust camshaft.

    2. Install the camshaft housing Click here.

    3. Apply a light coat of engine oil to the camshaft and camshaft timing exhaust gear.

    4. B001W7KE12

      Using the hexagonal portion of the camshaft, align and attach the knock pin of the camshaft with the pin hole of the camshaft timing exhaust gear.

      Text in Illustration
      *1 Key Groove
      *2 Knock Pin

      Note


      • Do not forcefully push on the camshaft timing exhaust gear. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing exhaust gear.

      • B001Z4ZE23

        Do not loosen or remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the camshaft timing exhaust gear assembly with a new one.

      Text in Illustration
      *1 Flange Bolt
      *a Do not remove

    5. Apply a light coat of engine oil to the threads and under the head of the bolt.

    6. B001YGGE02
      Text in Illustration
      *a Hold
      B001XPG Turn

      Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing exhaust gear with the bolt.

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

    7. Remove the camshaft bearing caps Click here.

    8. Check the camshaft timing exhaust gear lock.


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

    9. B001Z3XE14
      Text in Illustration
      *1 Advance Side Path
      *2 Retard Side Path
      *3 Open
      *4 Close
      B001YD9 Vinyl Tape

      Release the lock pin.


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

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

      3. B001YDJE04
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path

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

        Note

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

      4. B001XYKE10
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *3 Decompress
        *4 Hold Pressure

        Check that the camshaft timing exhaust gear 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 turns in the retard direction.

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

    10. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear 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 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.

    11. Check the lock at the most advanced position.


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

    12. Install the camshaft bearing caps Click here.

      Tech Tips

      Only install the exhaust camshaft.

    13. Install the camshaft housing Click here.

    14. B001XDYE02
      Text in Illustration
      *a Hold
      B001XPG Turn

      Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

    15. Remove the camshaft bearing caps Click here.

    16. B001Z4ZE24
      Text in Illustration
      *1 Flange Bolt
      *a Do not remove

      Remove the flange bolt and camshaft timing exhaust gear.

  8. INSPECT NO. 1 CHAIN SUB-ASSEMBLY

    B001X47E16
    Text in Illustration
    *1 Measuring Area

    1. Using a spring scale, pull the chain 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
      136.9 mm (5.39 in.)

      Tech Tips

      Perform the measurement at 3 random places.

      If the elongation is more than the maximum, replace the No. 1 chain.

  9. INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. Using a spring scale, pull the chain 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
      137.6 mm (5.42 in.)

      Tech Tips

      Perform the measurement at 3 random places.

      If the elongation is more than the maximum, replace the No. 2 chain.

  10. INSPECT CRANKSHAFT TIMING SPROCKET RH

    B001W27

    1. Wrap the chain around the sprocket.

    2. Using a vernier caliper, measure the sprocket diameter with the chain.

      Minimum sprocket diameter (with chain)
      61.4 mm (2.42 in.)

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

      Tech Tips

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

  11. INSPECT CRANKSHAFT TIMING SPROCKET LH

    B001W27

    1. Wrap the chain around the sprocket.

    2. Using a vernier caliper, measure the sprocket diameter with the chain.

      Minimum sprocket diameter (with chain)
      61.4 mm (2.42 in.)

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

      Tech Tips

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

  12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

    B001ZO4E05
    Text in Illustration
    *1 Plunger
    *2 Stopper Plate

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

      If necessary, replace the No. 1 chain tensioner.

  13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

    B001VX8E13
    Text in Illustration
    *1 Depth

    1. Check that the plunger moves smoothly.

    2. Measure the worn depth of the chain tensioner.

      Maximum depth
      0.9 mm (0.0354 in.)

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

  14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY

    B001XXZE13
    Text in Illustration
    *1 Depth

    1. Check that the plunger moves smoothly.

    2. Measure the worn depth of the chain tensioner.

      Maximum depth
      0.9 mm (0.0354 in.)

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

  15. INSPECT NO. 1 CHAIN TENSIONER SLIPPER


    1. B001XMIE12
      Text in Illustration
      *1 Depth

      for LH:

      Measure the worn depth of the chain tensioner slipper.

      Maximum depth
      1.0 mm (0.0394 in.)

      If the depth is more than the maximum, replace the No. 1 chain tensioner slipper.

    2. B001ZZME04
      Text in Illustration
      *1 Depth

      for RH:

      Measure the worn depth of the chain tensioner slipper.

      Maximum depth
      1.0 mm (0.0394 in.)

      If the depth is more than the maximum, replace the No. 1 chain tensioner slipper.

  16. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. B001YHKE05
      Text in Illustration
      *1 Depth

      for LH:

      Measure the worn depth of the 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.

    2. B001X13E08
      Text in Illustration
      *1 Depth

      for RH:

      Measure the worn depth of the 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.

  17. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH

    B00202N

    1. Using a precision straightedge and feeler gauge, measure the warpage of the surface where the exhaust manifold LH contacts the cylinder head.

      Maximum warpage
      0.7 mm (0.0276 in.)

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

  18. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH

    B001ZKB

    1. Using a precision straightedge and feeler gauge, measure the warpage of the surface where the exhaust manifold RH contacts the cylinder head.

      Maximum warpage
      0.7 mm (0.0276 in.)

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