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 free from dirt and foreign matter.

   • Only use clean engine oil.

   
   

   1. Place the valve lash adjuster assembly 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

      

      *1	Plunger	*2	Low Pressure Chamber
      *3	Check Ball	*4	High Pressure Chamber
      *5	Tapered Part	-	-
      *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 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 bleeding is not possible.

   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 assembly with a new one.

3. INSPECT CHAIN SUB-ASSEMBLY

   
   
   1. 

      *1	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 15 links.

      Maximum chain elongation
      115.2 mm (4.54 in.)

      Note

      Perform the measurement at 3 random places. Use the average of the measurements.

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

4. 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 15 links.

      Maximum chain elongation
      102.1 mm (4.02 in.)

      Note

      Perform the measurement at 3 random places. Use the average of the measurements.

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

5. INSPECT OIL PUMP DRIVE GEAR

   
   

   1. 

      Place the No. 2 chain sub-assembly around the oil pump drive gear.

   2. Using a vernier caliper, measure the diameter of the oil pump drive gear and No. 2 chain sub-assembly.

      Minimum gear diameter (with chain)
      48.2 mm (1.90 in.)

      Note

      The vernier caliper must be in contact with the chain rollers when measuring.

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

6. INSPECT OIL PUMP DRIVE SHAFT GEAR

   
   

   1. 

      Place the No. 2 chain sub-assembly around the oil pump drive shaft gear.

   2. Using a vernier caliper, measure the diameter of the oil pump drive shaft gear and No. 2 chain sub-assembly.

      Minimum gear diameter (with chain)
      48.2 mm (1.90 in.)

      Note

      The vernier caliper must be in contact with the chain rollers when measuring.

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

7. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

   
   

   1. 

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

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

      Minimum gear diameter (with chain)
      96.8 mm (3.81 in.)

      Note

      The vernier caliper must be in contact with the chain rollers when measuring.

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

8. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

   
   

   1. 

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

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

      Minimum gear diameter (with chain)
      96.8 mm (3.81 in.)

      Note

      The vernier caliper must be in contact with the chain rollers when measuring.

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

9. INSPECT CRANKSHAFT TIMING GEAR

   
   

   1. 

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

   2. Using a vernier caliper, measure the diameter of the crankshaft timing gear and chain sub-assembly.

      Minimum gear diameter (with chain)
      51.1 mm (2.01 in.)

      Note

      The vernier caliper must be in contact with the chain rollers when measuring.

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

10. INSPECT CHAIN TENSIONER SLIPPER

    
    

    1. 

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

       Maximum wear
       1.0 mm (0.0394 in.)

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

11. INSPECT NO. 1 CHAIN VIBRATION DAMPER

    
    

    1. 

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

       Maximum wear
       1.0 mm (0.0394 in.)

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

12. INSPECT NO. 2 CHAIN VIBRATION DAMPER

    
    

    1. 

       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.

13. INSPECT CHAIN TENSIONER PLATE

    
    

    1. 

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

       Maximum wear
       1.0 mm (0.0394 in.)

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

14. INSPECT NO. 1 CHAIN TENSIONER

    
    
    1. 

       *a	Raise
       *b	Move
       *c	Lock

       Check that the plunger moves smoothly when the cam is raised with your finger.

    2. Release the cam, and then check that the plunger is locked in place by the cam and does not move when pushed with your finger.

       If necessary, replace the No. 1 chain tensioner.

15. INSPECT CAMSHAFT

    
    

    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.

    2. Inspect the cam lobes.

       
       

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

          Standard cam lobe height
          42.816 to 42.916 mm (1.686 to 1.690 in.)

          Minimum cam lobe height
          42.666 mm (1.680 in.)

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

    3. Inspect the camshaft journals.

       
       

       1. Using a micrometer, measure the journal diameter.

          Standard Journal Diameter
          Journal Position Specified Condition No. 1 34.449 to 34.465 mm (1.356 to 1.357 in.) Other 22.949 to 22.965 mm (0.9035 to 0.9041 in.)

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

          Click here

16. INSPECT NO. 2 CAMSHAFT

    
    

    1. Inspect the No. 2 camshaft for 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
          0.04 mm (0.00157 in.)

          If the circle runout is more than the maximum, replace the No. 2 camshaft.

    2. Inspect the cam lobes.

       
       

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

          Standard cam lobe height
          44.336 to 44.436 mm (1.746 to 1.750 in.)

          Minimum cam lobe height
          44.186 mm (1.740 in.)

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

    3. Inspect the camshaft journals.

       
       

       1. Using a micrometer, measure the journal diameter.

          Standard Journal Diameter
          Journal Position Specified Condition No. 1 34.449 to 34.465 mm (1.356 to 1.357 in.) Other 22.949 to 22.965 mm (0.9035 to 0.9041 in.)

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

          Click here

17. INSPECT CYLINDER HEAD BOLT

    
    
    1. 

       *1	Measuring Length
       *2	Measuring Point

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

       Standard length
       146.8 to 148.2 mm (5.78 to 5.83 in.)

       Maximum length
       149.2 mm (5.87 in.)

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

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

       Standard diameter
       9.77 to 9.96 mm (0.385 to 0.392 in.)

       Minimum diameter
       9.4 mm (0.370 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 (refer to illustration) and find the area that has the smallest diameter.

18. INSPECT EXHAUST MANIFOLD

    
    

    1. 

       Using a precision straightedge and feeler gauge, measure the warpage on 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.