ENGINE UNIT INSPECTION

PROCEDURE


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


    1. A01MYGG

      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.

      SST
      09276-75010
      B003VWLC05
      *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 is very difficult to move.

      If the plunger can still be compressed after bleeding air 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
        0.08 mm (0.00315 in.)

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

        Tech Tips

        Check the oil clearance after replacing the camshaft.

        Click here

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

      Standard Cam Lobe Height
      Item Specified Condition
      Intake 43.940 to 44.040 mm (1.7299 to 1.7339 in.)
      Exhaust 44.090 to 44.190 mm (1.7358 to 1.7398 in.)
      Exhaust (for Fuel Pump) 56.450 to 56.550 mm (2.2224 to 2.2264 in.)
      Minimum Cam Lobe Height
      Item Specified Condition
      Intake 43.790 mm (1.7240 in.)
      Exhaust 43.940 mm (1.7299 in.)
      Exhaust (for Fuel Pump) 56.300 mm (2.2165 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.

      Click here

  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. B003VSAC03
      *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 assembly, be sure to release the straight pin lock before installing the camshaft timing gear assembly.

  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. B003WBKC01
      *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 camshaft timing exhaust gear assembly, be sure to release the straight pin lock before installing the camshaft timing exhaust gear assembly.

  6. INSPECT CYLINDER HEAD SET BOLT


    1. B003SWPC01
      *1 Measurement Length

      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.)

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

    2. B003TVSC09
      *1 Measurement Point
      *a Approximately 100 mm (3.94 in.)

      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.)

      Note


      • 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.

  7. INSPECT CHAIN SUB-ASSEMBLY


    1. B003TKJC02
      *1 Measurement Area

      Using a spring scale, pull the chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) and measure the length of the chain sub-assembly 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 sub-assembly.

  8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY

    B003TKJC03
    *1 Measurement Area

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

  9. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET


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

    2. B003UHH

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

      Minimum sprocket diameter (with chain sub-assembly)
      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 sub-assembly and crankshaft timeng gear or sprocket.

  10. INSPECT IDLE SPROCKET ASSEMBLY


    1. Place the chain sub-assembly around the idle sprocket assembly.

    2. B003TDQ

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

      Minimum sprocket diameter (with chain sub-assembly)
      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 sub-assembly and idle sprocket assembly.

  11. INSPECT IDLE GEAR SHAFT OIL CLEARANCE


    1. B003SYO

      Using a micrometer, measure the No. 1 idle gear shaft diameter.

      Standard diameter
      22.987 to 23.000 mm (0.905 to 0.906 in.)
    2. B003TXC

      Using a caliper gauge, measure the inside diameter of the idle sprocket assembly.

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

    3. Subtract the No. 1 idle gear shaft diameter measurement from the idle sprocket assembly inside diameter measurement.

      Standard oil clearance
      0.020 to 0.043 mm (0.00079 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 No. 1 idle gear shaft and idle sprocket assembly.

  12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B003UB3C01
      *1 Plunger
      *2 Stopper Plate

      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 assembly.

  13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

    B003VGLC02
    *a Depth
    *b Moves Smoothly

    1. Check that the plunger moves smoothly.

    2. Measure the depth of wear of the No. 2 chain tensioner assembly.

      Maximum depth
      0.9 mm (0.0354 in.)

      If the depth is more than the maximum, replace the No. 2 chain tensioner assembly.

  14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY

    B003UXEC02
    *a Depth
    *b Moves Smoothly

    1. Check that the plunger moves smoothly.

    2. Measure the depth of wear of the No. 3 chain tensioner assembly.

      Maximum depth
      0.9 mm (0.0354 in.)

      If the depth is more than the maximum, replace the No. 3 chain tensioner assembly.

  15. INSPECT CHAIN TENSIONER SLIPPER


    1. B003TO2C03
      *a 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. B003UQ1C03
      *a 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. B003WSDC03
      *a 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 sub-assembly RH and camshaft journals.

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

      3. B003VHBC04
        *1 Plastigage

        Lay a strip of Plastigage across each camshaft journal.

      4. Install the camshaft bearing caps.

        Note

        Do not turn the camshafts.

        Click here

      5. Remove the camshaft bearing caps.

        Click here

      6. B003X0SC06
        *1 Plastigage
        *2 No. 1 Journal
        *3 Other Journals
        *a Intake Side
        *b Exhaust Side

        Measure the Plastigage at its widest point.

        Standard Oil Clearance
        Item Specified Condition
        Exhaust side No. 1 journal 0.031 to 0.078 mm (0.00122 to 0.00307 in.)
        Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.)
        Maximum Oil Clearance
        Item Specified Condition
        Exhaust side 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, replace the camshaft.

        If the oil clearance is still more than the maximum after replacing the camshaft, replace the camshaft housing sub-assembly RH.

    2. for Bank 2:


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

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

      3. B003X3CC03
        *1 Plastigage

        Lay a strip of Plastigage across each camshaft journal.

      4. Install the camshaft bearing caps.

        Note

        Do not turn the camshafts.

        Click here

      5. Remove the camshaft bearing caps.

        Click here

      6. B003UZ4C06
        *1 Plastigage
        *2 No. 1 Journal
        *3 Other Journals
        *a Intake Side
        *b Exhaust Side

        Measure the Plastigage at its widest point.

        Standard Oil Clearance
        Item Specified Condition
        Exhaust side No. 1 journal 0.031 to 0.078 mm (0.00122 to 0.00307 in.)
        Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.)
        Maximum Oil Clearance
        Item Specified Condition
        Exhaust side 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, replace the camshaft.

        If the oil clearance is still more than the maximum after replacing the camshafts, replace the camshaft housing sub-assembly LH.

  19. INSPECT EXHAUST MANIFOLD


    1. B003WRI

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

      Maximum warpage
      0.70 mm (0.02756 in.)

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

  20. INSPECT INTAKE MANIFOLD


    1. B003T5VC02
      *a Intake Air 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.