ENGINE UNIT INSPECTION

PROCEDURE


  1. 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 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. 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.

      A000P6JE01
      SST
      09276-75010
      Text in Illustration
      *1 Tapered Path
      *2 Plunger
      *3 Low Pressure Chamber
      *4 Check Ball
      *5 High Pressure Chamber
      *a CORRECT
      *b INCORRECT

    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 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.

  3. INSPECT CAMSHAFT


    1. 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
        0.04 mm (0.00157 in.)

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

        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 44.318 to 44.418 mm (1.7448 to 1.7487 in.)
      Exhaust 44.341 to 44.441 mm (1.7457 to 1.7496 in.)
      Minimum Cam Lobe Height
      Item Specified Condition
      Intake 44.168 mm (1.7389 in.)
      Exhaust 44.191 mm (1.7398 in.)

    3. 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. Install the camshaft timing gear assembly Click here.

    2. Inspect the camshaft timing gear assembly Click here.

    3. A000ODSE01
      Text in Illustration
      *1 Flange Bolt
      *2 Straight Pin
      *a Do Not Remove

      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. Install the camshaft timing exhaust gear assembly Click here.

    2. Inspect the camshaft timing exhaust gear assembly Click here.

    3. A000ORZE07
      Text in Illustration
      *1 Flange Bolt
      *2 Straight Pin
      *a Do Not Remove

      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

    A000SQCE03

    1. Using a vernier caliper, measure the length of the cylinder head set bolt from the seat to the end.

      Standard length
      141.3 to 142.7 mm (5.56 to 5.62 in.)
      Maximum length
      143.7 mm (5.66 in.)
      Text in Illustration
      *1 Measurement Length

      If the length is more than the maximum, replace the cylinder head set bolt.

    2. A000PJU

      Using a vernier caliper, measure the diameter of the elongated thread at the narrowest visible area.

      Standard diameter
      10.80 to 11.00 mm (0.425 to 0.433 in.)
      Minimum diameter
      10.70 mm (0.421 in.)

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

      Tech Tips

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

  7. INSPECT CHAIN SUB-ASSEMBLY


    1. A000Q74E04
      Text in Illustration
      *1 Measurement Area

      Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33 lbf) and measure the length of the chain using a vernier caliper.

      Maximum chain elongation
      136.9 mm (5.39 in.)

      Tech Tips

      Perform the measurement at 3 random places. If a measurement is more than the maximum, replace the chain.

  8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. Using a spring scale, pull the No. 2 chain with a force of 147 N (15 kgf, 33 lbf) and measure the length of the No. 2 chain using a vernier caliper.

      Maximum chain elongation
      137.6 mm (5.42 in.)

      Tech Tips

      Perform the measurement at 3 random places. If a measurement is more than the maximum, replace the No. 2 chain.

  9. INSPECT CRANKSHAFT TIMING SPROCKET


    1. Place the chain around the crankshaft timing sprocket.

    2. A000S9F

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

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

  10. INSPECT IDLE SPROCKET ASSEMBLY


    1. Place the chain around the idle sprocket.

    2. A000NVM

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

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

  11. INSPECT IDLE GEAR SHAFT OIL CLEARANCE


    1. Using a micrometer, measure the idle gear shaft diameter.

      Standard idle gear shaft diameter
      22.987 to 23.000 mm (0.905 to 0.906 in.)

    2. Using a caliper gauge, measure the inside diameter of the idle gear.

      Standard idle gear inside diameter
      23.020 to 23.030 mm (0.906 to 0.907 in.)

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

      Standard oil clearance
      0.020 to 0.043 mm (0.000787 to 0.00169 in.)
      Maximum oil clearance
      0.093 mm (0.00366 in.)

      If the thrust oil clearance is more than the maximum, replace the idle gear shaft and idle gear.

  12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A000SK1E03
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate
      *a Moves Smoothly

      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.

  13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A000R9AE01
      Text in Illustration
      *1 Depth
      *a Moves Smoothly

      Check that the plunger moves smoothly.

    2. Measure the depth of wear 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


    1. A000T03E01
      Text in Illustration
      *1 Depth
      *a Moves Smoothly

      Check that the plunger moves smoothly.

    2. Measure the depth of wear 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 CHAIN TENSIONER SLIPPER


    1. A000P2KE04
      Text in Illustration
      *1 Depth

      Measure the depth of wear 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.

  16. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. A000PXPE06
      Text in Illustration
      *1 Depth

      Measure the depth of wear 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.

  17. INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. A000QKSE03
      Text in Illustration
      *1 Depth

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

      Maximum depth
      1.0 mm (0.0394 in.)

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

  18. INSPECT CAMSHAFT OIL CLEARANCE


    1. for Bank 1:


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

      2. Place the camshafts on the camshaft housing.

      3. A000QSPE01
        Text in Illustration
        *1 Plastigage

        Lay a strip of Plastigage across each camshaft journal.

      4. Install the camshaft bearing caps Click here.

        Note

        Do not turn the camshaft.

      5. Remove the camshaft bearing caps Click here.

      6. A000MTVE02
        Text in Illustration
        *1 Plastigage
        *2 No. 1 Journal
        *3 No. 2 Journal
        *4 No. 3 Journal
        *5 No. 4 Journal
        *6 No. 5 Journal

        Measure the Plastigage at its widest point.

        Standard Oil Clearance
        Item Specified Condition
        No. 1 journal 0.032 to 0.071 mm (0.00122 to 0.00280 in.)
        No. 2, 3, 4 journals 0.025 to 0.062 mm (0.000984 to 0.00240 in.)
        No. 5 journal 0.015 to 0.052 mm (0.000591 to 0.00205 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, inspect the inner compression spring. If necessary, replace the camshaft. If the oil clearance is still more than the maximum after replacing the camshaft, replace the camshaft housing.

    2. for Bank 2:


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

      2. Place the camshafts on the camshaft housing.

      3. A000O6JE01
        Text in Illustration
        *1 Plastigage

        Lay a strip of Plastigage across each camshaft journal.

      4. Install the camshaft bearing caps Click here.

        Note

        Do not turn the camshaft.

      5. Remove the camshaft bearing caps Click here.

      6. A000Q83E02
        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 0.032 to 0.071 mm (0.00122 to 0.00280 in.)
        Other journals 0.025 to 0.062 mm (0.000984 to 0.00240 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, inspect the inner compression spring. If necessary, replace the camshaft. If the oil clearance is still more than the maximum after replacing the camshaft, replace the camshaft housing.

  19. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY


    1. A000N48

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

      Maximum warpage
      0.70 mm (0.0276 in.)

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

  20. INSPECT INTAKE MANIFOLD


    1. A000NEZE01
      Text in Illustration
      *a Surge Tank Side
      *b Cylinder Head Side

      Using a precision straightedge and feeler gauge, measure the warpage of the surfaces which contact the cylinder head and intake air surge tank.

      Maximum warpage
      0.10 mm (0.00394 in.)

      If the warpage is more than the maximum, replace the intake manifold.