ENGINE UNIT INSPECTION

PROCEDURE


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


    1. A000S8Y

      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

    Note


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

    • Use only clean engine oil.


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

      A000NEQE05
      Text in Illustration
      *a Correct *b Incorrect
      *c Taper Part *d Plunger
      *e Low Pressure Chamber *f Check Ball
      *g High Pressure Chamber - -

    2. 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 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 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


    1. Inspect the camshaft runout.


      1. Place the camshaft on V-blocks. 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 camshaft oil clearance after replacing the camshaft.

    2. Inspect the cam lobes. (for intake valve)


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

        Standard cam lobe height
        44.183 to 44.283 mm (1.739 to 1.743 in.)
        Minimum cam lobe height
        44.073 mm (1.735 in.)

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

        Tech Tips

        Check the camshaft oil clearance after replacing the camshaft.

    3. Inspect the cam lobes. (for fuel pump drive)


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

        Standard cam lobe height
        40.554 to 40.654 mm (1.597 to 1.601 in.)
        Minimum cam lobe height
        40.554 mm (1.597 in.)

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

        Tech Tips

        Check the camshaft oil clearance after replacing the camshaft.

    4. 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 camshaft oil clearance.

  4. INSPECT NO. 2 CAMSHAFT


    1. Inspect the No. 2 camshaft runout.


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

        Tech Tips

        Check the camshaft oil clearance after replacing the No. 2 camshaft.

    2. Inspect the cam lobes.


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

        Standard cam lobe height
        43.533 to 43.633 mm (1.714 to 1.718 in.)
        Minimum cam lobe height
        43.423 mm (1.710 in.)

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

        Tech Tips

        Check the camshaft oil clearance after replacing the No. 2 camshaft.

    3. 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 camshaft oil clearance.

  5. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Secure the camshaft between aluminum plates in a vise.

      Note

      Do not damage the camshaft.

    2. Install the camshaft timing gear assembly to the camshaft Click here.

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


      1. A000P7SE03
        Text in Illustration
        *a Lock Pin Released
        *b Lock Pin Locked
        *c Pin Hole
        *d Lock Check Point

        Make sure that the camshaft timing gear assembly is locked.

    4. Release the lock pin.


      1. A000OZDE03
        Text in Illustration
        *a Retard Side Path
        *b Advance Side Path
        *c Open
        *d Close
        *e Knock Pin
        B002BZV Rubber Piece
        B002BPS Vinyl Tape

        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 3 of the paths with pieces of rubber.

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

      4. A000Q73

        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).

        Note


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

        • 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.

    5. Check for smooth rotation.


      1. Turn the camshaft timing gear assembly 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.

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

    7. Remove the bolt and camshaft timing gear assembly Click here.

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

    9. Inspect the camshaft timing gear assembly diameter.


      1. A000SOYE04
        Text in Illustration
        *a Chain Roller

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

        Minimum diameter (with chain sub-assembly)
        115.12 mm (4.53 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. Secure the No. 2 camshaft between aluminum plates in a vise.

      Note

      Do not damage the No. 2 camshaft.

    2. Install the camshaft timing exhaust gear assembly to the No. 2 camshaft Click here.

    3. Release the lock pin.


      1. A000NJ7E03
        Text in Illustration
        *a Advance Side Path
        *b Retard Side Path
        *c Open
        *d Close
        *e Knock Pin
        B002BZV Rubber Piece
        B002BPS Vinyl Tape

        Clean the No. 2 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 No. 2 camshaft. Plug 2 paths with rubber pieces.

      3. Make a hole in the vinyl tape placed over the 2 oil holes that are not plugged with rubber pieces.

      4. A000R6TE08
        Text in Illustration
        *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 retard side path).

        Note

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

      5. A000S6DE07
        Text in Illustration
        *a Advance Side Path
        *b Retard Side Path
        *c Hold Pressure
        *d Decompress

        Check 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.

      6. 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 (21.5 to 23.5°) 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.

    5. Remove the vinyl tape and rubber pieces from the No. 2 camshaft.

    6. Remove the bolt and camshaft timing exhaust gear assembly Click here.

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

    8. Inspect the camshaft timing exhaust gear assembly diameter.


      1. A000RC9E07
        Text in Illustration
        *a Chain Roller

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

        Minimum diameter (with chain sub-assembly)
        115.12 mm (4.53 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 CHAIN SUB-ASSEMBLY


    1. A000S1JE27
      Text in Illustration
      *a Measurement Area

      Using a spring scale, 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 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 CRANKSHAFT TIMING GEAR OR SPROCKET


    1. A000QN5E03
      Text in Illustration
      *a Chain Roller

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

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

      Minimum sprocket diameter (with chain sub-assembly)
      59.94 mm (2.36 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 or sprocket.

  9. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A000O3IE03
      Text in Illustration
      *a Plunger
      *b 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.

  10. INSPECT CHAIN TENSIONER SLIPPER


    1. A000PKIE02
      Text in Illustration
      *a Depth

      Using a vernier caliper, 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 chain tensioner slipper.

  11. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. A000N2RE07
      Text in Illustration
      *a Depth

      Using a vernier caliper, measure the worn 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.

  12. INSPECT TIMING CHAIN GUIDE


    1. A000P9BE11
      Text in Illustration
      *a Depth

      Using a vernier caliper, measure the worn 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.

  13. INSPECT BALANCE SHAFT THRUST CLEARANCE


    1. A000OGIE02
      Text in Illustration
      *1 No. 1 Balance Shaft

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

      Standard thrust clearance
      0.07 to 0.11 mm (0.00276 to 0.00433 in.)
      Maximum thrust clearance
      0.11 mm (0.00433 in.)

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

    2. A000N6KE02
      Text in Illustration
      *1 No. 2 Balance Shaft

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

      Standard thrust clearance
      0.07 to 0.11 mm (0.00276 to 0.00433 in.)
      Maximum thrust clearance
      0.11 mm (0.00433 in.)

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

  14. INSPECT BALANCE SHAFT BACKLASH


    1. A000R85E02
      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 balance shaft and No. 2 balance shaft as shown in the illustration.

      Standard backlash
      0.04 to 0.16 mm (0.00157 to 0.00630 in.)
      Maximum backlash
      0.16 mm (0.00630 in.)

      Note

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

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

  15. INSPECT CYLINDER HEAD SET BOLT


    1. A000SGTE02
      Text in Illustration
      *a Measurement Point
      *b Approximately 106 mm (4.17 in.)

      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.)

      Tech Tips


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

  16. INSPECT CAMSHAFT OIL CLEARANCE

    Note

    Do not turn the camshafts.


    1. Clean the camshaft bearing caps, camshaft housing sub-assembly and camshaft journals.

    2. Place the camshafts on the camshaft housing sub-assembly.

    3. A000RXKE01
      Text in Illustration
      *a Plastigage

      Lay a strip of Plastigage across each camshaft journal.

    4. Install the camshaft bearing caps Click here.

      Note


      • Do not apply engine oil to the camshaft bearing cap.

      • When installing, do not turn the camshaft and No. 2 camshaft.

    5. Remove the camshaft bearing caps Click here.

      Note

      When removing, do not turn the camshaft and No. 2 camshaft.

    6. A000SV9E03
      Text in Illustration
      *a No. 1 Journal
      *b Other Journal
      *c Plastigage

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      Item Specified Condition
      Intake No. 1 Journal 0.035 to 0.072 mm (0.00138 to 0.00283 in.)
      Exhaust No. 1 Journal 0.049 to 0.086 mm (0.00193 to 0.00339 in.)
      Other Journals 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 0.095 mm (0.00374 in.)
      Other Journals 0.085 mm (0.00335 in.)

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

      If necessary, replace the camshaft housing sub-assembly.