ENGINE UNIT INSPECTION


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


    1. A01I5IK

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

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

  2. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    A01I3NLE02
    Text in Illustration
    *1 Plunger
    *2 Check Ball
    *a CORRECT
    *b INCORRECT
    *c Taper Part
    *d Low Pressure Chamber
    *e High Pressure Chamber

    Note


    • Keep the adjuster free from dirt and foreign matter.

    • Use only clean engine oil.


    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 the air.

      OK
      Plunger moves up and down.

      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 is very difficult to move.

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

  3. INSPECT CAMSHAFT OIL CLEARANCE

    Note

    Do not turn the camshafts.


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

    2. Place the camshafts on the camshaft housing.

    3. A01I37KE01
      Text in Illustration
      *1 Plastigage

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

    4. Install the camshaft bearing caps Click here.

    5. Install the camshaft housing sub-assembly Click here.

    6. Remove the camshaft bearing caps Click here.

    7. A01I3ITE01
      Text in Illustration
      *1 Plastigage
      *2 No. 1 Journal
      *3 Other Journal

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      Item Specified Condition
      Intake No. 1 journal 0.035 to 0.072 mm (0.00137 to 0.00283 in.)
      Exhaust No. 1 journal 0.005 to 0.054 mm (0.000197 to 0.00213 in.)
      Other journal 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
      Maximum Oil Clearance
      Item Specified Condition
      Intake No. 1 journal 0.085 mm (0.00335 in.)
      Exhaust No. 1 journal 0.085 mm (0.00335 in.)
      Other journal 0.085 mm (0.00335 in.)

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

  4. INSPECT CAMSHAFT THRUST CLEARANCE


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

    2. Place the camshafts on the camshaft housing.

    3. Install the camshaft bearing caps Click here.

    4. Install the camshaft housing sub-assembly Click here.

    5. A01I2FT

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

      Standard Thrust Clearance
      Item Specified Condition
      Intake 0.060 to 0.155 mm (0.00236 to 0.00610 in.)
      Exhaust 0.060 to 0.155 mm (0.00236 to 0.00610 in.)
      Maximum Thrust Clearance
      Item Specified Condition
      Intake 0.170 mm (0.00669 in.)
      Exhaust 0.170 mm (0.00669 in.)

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

  5. INSPECT CAMSHAFT


    1. A01I2T6

      Inspect the camshaft runout.


      1. Place the camshaft on V-blocks.

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

        Maximum circle runout
        0.03 mm (0.00118 in.)

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

        Tech Tips

        Check the oil clearance after replacing the camshaft.

    2. A01I5WR

      Inspect the cam lobes.


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

        Standard Cam Lobe Height
        Item Specified Condition
        Intake 43.814 to 43.914 mm (1.725 to 1.729 in.)
        Exhaust 42.939 to 43.039 mm (1.691 to 1.694 in.)
        Minimum Cam Lobe Height
        Item Specified Condition
        Intake 43.704 mm (1.721 in.)
        Exhaust 42.829 mm (1.686 in.)

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

    3. A01I4VW

      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 (1.356 to 1.357 in.)
        Other journals 22.959 to 22.975 mm (0.904 to 0.905 in.)

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

  6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01I37LE02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

      Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

    2. A01I5YTE11
      Text in Illustration
      *1 Camshaft Timing Gear
      *2 Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

      Check that there is no clearance between the camshaft timing gear and camshaft flange.

    3. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.

      Note

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    4. 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.

    5. A01I60SE05

      Release the lock pin.

      Text in Illustration
      *1 Rubber
      *2 Vinyl Tape
      *3 Knock Pin
      *a Retard Side Path
      *b Advance Side Path
      *c Open
      *d Close

      1. Clean the camshaft journal with non-residue solvent.

      2. 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 grooves of the camshaft. Plug three of the paths with pieces of rubber.

      3. Open a hole at port A shown in the illustration.

      4. A01I4Y6

        While applying approximately 200 kPa (2.0 kgf/ cm2, 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        CAUTION:

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

        Note

        Do not allow the camshaft timing gear assembly to lock. If it locks, 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.

    6. Check for smooth rotation.


      1. Turn the camshaft timing gear within its movable range (26.5 to 28.5°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.

        Note

        Do not allow the camshaft timing gear assembly to lock.

        If it locks, release the lock pin again.

    7. Remove the vinyl tape and rubber pieces from the camshaft.

    8. Remove the bolt and camshaft timing gear.

  7. INSPECT CHAIN SUB-ASSEMBLY


    1. A01I4VUE11
      Text in Illustration
      *a Measurement Area

      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
      137.7 mm (5.42 in.)

      Tech Tips

      Perform the measurement at 3 random places.

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

  8. INSPECT CAMSHAFT TIMING SPROCKET


    1. A01I42B

      Place the chain around the sprocket.

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

      Minimum sprocket diameter (with chain)
      115.12 mm (4.53 in.)

      If the diameter is less than the minimum, replace the chain sub-assembly and camshaft timing sprocket.

      Tech Tips

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

  9. INSPECT CRANKSHAFT TIMING SPROCKET


    1. A01I3UD

      Place the chain around the sprocket.

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

      Minimum sprocket diameter (with chain)
      59.94 mm (2.36 in.)

      If the diameter is less than the minimum, replace the chain sub-assembly and crankshaft timing sprocket.

      Tech Tips

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

  10. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01I2TDE01
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

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

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

  11. INSPECT CHAIN TENSIONER SLIPPER


    1. A01I33UE05
      Text in Illustration
      *a Depth

      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.

  12. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. A01I3WYE05
      Text in Illustration
      *a Depth

      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.

  13. INSPECT TIMING CHAIN GUIDE


    1. A01I4A2E05
      Text in Illustration
      *a Depth

      Measure the wear depth of the timing chain guide.

      Maximum depth
      1.0 mm (0.0394 in.)

      If the depth is more than the maximum, replace the timing chain guide.

  14. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE


    1. A01I5QM

      Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.

      Standard thrust clearance
      0.05 to 0.09 mm (0.00197 to 0.00354 in.)
      Maximum thrust clearance
      0.09 mm (0.00354 in.)

      If the thrust clearance is more than the maximum, replace the engine balancer assembly.

  15. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE


    1. A01I472

      Using a dial indicator, measure the thrust clearance while moving the No. 2 balance shaft back and forth.

      Standard thrust clearance
      0.05 to 0.09 mm (0.00197 to 0.00354 in.)
      Maximum thrust clearance
      0.09 mm (0.00354 in.)

      If the thrust clearance is more than the maximum, replace the engine balancer assembly.

  16. INSPECT BALANCE SHAFT BACKLASH


    1. A01I3GAE04
      Text in Illustration
      *a Fix

      Secure the No. 2 balance shaft in place, and then using a dial indicator, measure the backlash of the No. 1 and No. 2 balance shafts as shown in the illustration.

      Standard backlash
      0.04 to 0.17 mm (0.00157 to 0.00669 in.)
      Maximum backlash
      0.17 m (0.00669 in.)

      Note

      Measure at 3 or more areas around the circumference of the No. 1 and No. 2 balance shafts.

      If the backlash is more than the maximum, replace the engine balancer assembly.

  17. INSPECT CYLINDER HEAD BOLT


    1. A01I47IE15
      Text in Illustration
      *a Measurement Point

      Using a vernier caliper, measure the diameter of the threads at the measurement point.

      Standard diameter
      10.85 to 11.00 mm (0.427 to 0.433 in.)
      Minimum diameter
      10.6 mm (0.417 in.)
      Measurement point (distance from the seat)
      106 mm (4.17 in.)

      Tech Tips


      • If the diameter is less than the minimum, replace the cylinder head bolt. Failure to do so may lead to engine damage.

      • If there is any thread deformation, replace the cylinder head bolt with a new one.

  18. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A01I3ES

      Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts the cylinder head.

      Maximum warpage
      0.7 mm (0.0276 in.)

      If the warpage is more than the maximum, replace the exhaust manifold converter sub-assembly.