ENGINE UNIT INSPECTION

PROCEDURE

1. INSPECT CHAIN SUB-ASSEMBLY

   
   
   1. 

      Text in Illustration

      *a	Measuring Area

      Pull the 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 16 links.

      Maximum chain elongation
      147.5 mm (5.81 in.)

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

      Note

      Perform the measurement at 3 random places.

2. INSPECT NO. 2 CHAIN SUB-ASSEMBLY

   
   

   1. Pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33.0 lbf).

   2. Using a vernier caliper, measure the length of 16 links.

      Maximum chain elongation
      123.6 mm (4.87 in.)

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

      Note

      Perform the measurement at 3 random places.

3. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

   
   
   1. 

      Text in Illustration

      *a	Plunger
      *b	Stopper Plate

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

4. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

   
   
   1. 

      Text in Illustration

      *a	Plunger
      *b	Stopper Plate

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

5. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

   
   

   1. 

      Measure the distance between the most worn out camshaft timing gear tip and the beginning of the worn area below the tip.

      Minimum distance
      1.0 mm (0.0394 in.)

      Text in Illustration

      Worn Area

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

      If the worn area is too small or difficult to distinguish from a normal area, perform the following 2 steps.

   2. Wrap the chain sub-assembly around the camshaft timing gear assembly.

   3. Using a vernier caliper, measure the sprocket diameter with the chain sub-assembly.

      Minimum sprocket diameter (with chain)
      113.8 mm (4.48 in.)

      Tech Tips

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

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

6. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

   
   

   1. 

      Measure the distance between the most worn out camshaft timing gear tip and the beginning of the worn area below the tip.

      Minimum distance
      1.0 mm (0.0394 in.)

      Text in Illustration

      Worn Area

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

      If the worn area is too small or difficult to distinguish from a normal area, perform the following 2 steps.

   2. Wrap the chain sub-assembly around the camshaft timing exhaust gear assembly.

   3. Using a vernier caliper, measure the sprocket diameter with the chain sub-assembly.

      Minimum sprocket diameter (with chain)
      113.8 mm (4.48 in.)

      Tech Tips

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

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

7. INSPECT CRANKSHAFT TIMING GEAR

   
   

   1. 

      Measure the distance between the most worn out crankshaft timing gear tip and the beginning of the worn area below the tip.

      Minimum distance
      1.0 mm (0.0394 in.)

      Text in Illustration

      Worn Area

      If the distance is less than the minimum, replace the crankshaft timing gear.

      If the worn area is too small or difficult to distinguish from a normal area, perform the following 2 steps.

   2. Wrap the chain sub-assembly around the crankshaft timing gear.

   3. Using a vernier caliper, measure the sprocket diameter with the chain sub-assembly.

      Minimum sprocket diameter (with chain)
      59.4 mm (2.34 in.)

      Tech Tips

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

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

8. INSPECT CHAIN TENSIONER SLIPPER

   
   
   1. 

      Text in Illustration

      *a

      Wear

      Using a vernier caliper, measure the chain tensioner slipper wear.

      Maximum wear
      2.0 mm (0.0787 in.)

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

9. INSPECT NO. 1 CHAIN VIBRATION DAMPER

   
   
   1. 

      Text in Illustration

      *a

      Wear

      Using a vernier caliper, measure the No. 1 chain vibration damper wear.

      Maximum wear
      2.0 mm (0.0787 in.)

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

10. INSPECT TIMING CHAIN GUIDE

    
    

    1. 

       Using a vernier caliper, measure the timing chain guide wear.

       Maximum wear
       0.5 mm (0.0197 in.)

       Text in Illustration

       Wear

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

11. INSPECT NO. 2 CRANKSHAFT TIMING SPROCKET

    
    

    1. Wrap the chain around the No. 2 crankshaft timing sprocket.

    2. 

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

       Minimum sprocket diameter (with chain)
       96.7 mm (3.81 in.)

       Tech Tips

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

       If the diameter is less than the minimum, replace the No. 2 chain sub-assembly and No. 2 crankshaft timing sprocket.

12. INSPECT BALANCESHAFT DRIVE GEAR SUB-ASSEMBLY

    
    

    1. Wrap the No. 2 chain sub-assembly around the balanceshaft drive gear sub-assembly.

    2. 

       Using a vernier caliper, measure the sprocket diameter with the No. 2 chain sub-assembly.

       Minimum sprocket diameter (with chain)
       75.9 mm (2.99 in.)

       Tech Tips

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

       If the diameter is less than the minimum, replace the No. 2 chain sub-assembly and balanceshaft drive gear sub-assembly.

13. INSPECT NO. 2 CHAIN VIBRATION DAMPER

    
    
    1. 

       Text in Illustration

       *a

       Wear

       Using a vernier caliper, measure the No. 2 chain vibration damper wear.

       Maximum wear
       1.0 mm (0.0394 in.)

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

14. INSPECT NO. 3 CHAIN VIBRATION DAMPER

    
    
    1. 

       Text in Illustration

       *a

       Wear

       Using a vernier caliper, measure the No. 3 chain vibration damper wear.

       Maximum wear
       1.0 mm (0.0394 in.)

       If the wear is more than the maximum, replace the No. 3 chain vibration damper.

15. INSPECT NO. 4 CHAIN VIBRATION DAMPER

    
    
    1. 

       Text in Illustration

       *a

       Wear

       Using a vernier caliper, measure the No. 4 chain vibration damper wear.

       Maximum wear
       1.0 mm (0.0394 in.)

       If the wear is more than the maximum, replace the No. 4 chain vibration damper.

16. INSPECT CYLINDER HEAD SET BOLT

    
    
    1. 

       Text in Illustration

       *a	Measuring area
       *b	Distance

       Using a vernier caliper, measure the diameter of the most elongated threads in the measuring area.

       Standard outside diameter
       10.76 to 10.97 mm (0.424 to 0.432 in.)

       Minimum outside diameter
       10.40 mm (0.409 in.)

       Distance
       30 mm (1.18 in.)

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

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

17. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Note

    
    

    • Keep the lash adjuster free from dirt and foreign objects.

    • Only use clean engine oil.

    
    
    1. 

       Text in Illustration

       *a	CORRECT
       *b	INCORRECT
       *c	Taper Part
       *d	Plunger
       *e	Low Pressure Chamber
       *f	Check Ball
       *g	High Pressure Chamber

       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.

       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.

18. INSPECT CAMSHAFT

    
    

    1. Check 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.

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

       Standard cam lobe height
       42.855 to 42.955 mm (1.687 to 1.691 in.)

       Minimum cam lobe height
       42.855 mm (1.687 in.)

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

    3. Using a micrometer, measure the journal diameter.

       Standard Journal Diameter
       Item Specified Condition No. 1 journal 35.949 to 35.965 mm (1.415 to 1.416 in.) Other journal 26.959 to 26.975 mm (1.061 to 1.062 in.)

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

19. INSPECT NO. 2 CAMSHAFT

    
    

    1. Check the No. 2 camshaft runout.

       
       

       1. Place the No. 2 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 No. 2 camshaft.

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

       Standard cam lobe height
       42.854 to 42.954 mm (1.687 to 1.691 in.)

       Minimum cam lobe height
       42.854 mm (1.687 in.)

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

    3. Using a micrometer, measure the journal diameter.

       Standard Journal Diameter
       Item Specified Condition No. 1 journal 35.949 to 35.965 mm (1.415 to 1.416 in.) Other journal 26.959 to 26.975 mm (1.061 to 1.062 in.)

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

20. INSPECT CAMSHAFT THRUST CLEARANCE

    Click here

21. INSPECT CAMSHAFT OIL CLEARANCE

    Click here

22. INSPECT EXHAUST MANIFOLD

    
    

    1. 

       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.