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.

      SST
      09276-75010
      B003VXPC01
      *a CORRECT *b INCORRECT
      *c Tapered Path *d Plunger
      *e Low Pressure Chamber *f Check Ball
      *g High Pressure Chamber - -

    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 assembly 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
        0.03 mm (0.00118 in.)

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

        Tech Tips

        Check the oil clearance after replacing the camshaft.

    2. B003UF7

      Inspect the cam lobes. (for intake and exhaust valve)


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

        Standard Cam Lobe Height
        Item Specified Condition
        Intake Side of Bank 1 44.3229 to 44.4229 mm (1.744 to 1.748 in.)
        Exhaust Side of Bank 1 44.4377 to 44.5377 mm (1.749 to 1.753 in.)
        Intake Side of Bank 2 44.3221 to 44.4221 mm (1.744 to 1.748 in.)
        Exhaust Side of Bank 2 44.4356 to 44.5356 mm (1.749 to 1.753 in.)
        Minimum Cam Lobe Height
        Item Specified Condition
        Intake Side of Bank 1 44.2229 mm (1.741 in.)
        Exhaust Side of Bank 1 44.3377 mm (1.746 in.)
        Intake Side of Bank 2 44.2221 mm (1.741 in.)
        Exhaust Side of Bank 2 44.3356 mm (1.745 in.)
    3. B003V0B

      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
        40.454 mm (1.593 in.)

    4. Using a micrometer, measure the journal diameter. (for Exhaust Side of Bank 1)

      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.)

    5. Using a micrometer, measure the journal diameter. (except Exhaust Side of Bank 1)

      Standard Journal Diameter
      Item Specification
      No. 1 Journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
      No. 2, 3, 4 Journals 25.959 to 25.975 mm (1.0220 to 1.0226 in.)
      No. 5 Journal 25.969 to 25.985 mm (1.022 to 1.023 in.)

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

  4. INSPECT CYLINDER HEAD SET BOLT

    B003TMHC07
    *a Measurement Length

    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.)

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

    2. B003TVSC16
      *a Measuring Point
      *b 100 mm (3.93 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.)

      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.

  5. INSPECT CHAIN SUB-ASSEMBLY


    1. B003UWGC01
      *a 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 using a vernier caliper.

      Maximum chain elongation
      136.7 mm (5.38 in.)

      Tech Tips

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

  6. INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. B003UWGC01
      *a Measurement Area

      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 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.

  7. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET


    1. Place the chain around the crankshaft timing gear or sprocket.

    2. B003UHH

      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 sub-assembly and crankshaft timing gear or sprocket.

  8. INSPECT IDLE SPROCKET ASSEMBLY


    1. Place the chain around the idle sprocket assembly.

    2. B003TDQ

      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 sub-assembly and idle sprocket assembly.

  9. INSPECT IDLE GEAR SHAFT OIL CLEARANCE


    1. Using a micrometer, measure the No. 1 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 sprocket assembly.

      Standard idle gear inside 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 (0.00078 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.

  10. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B003UK0C11
      *a Moves Smoothly
      *b Plunger
      *c 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.

  11. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B003WR3C01
      *a Moves Smoothly
      *b Depth

      Check that the plunger moves smoothly.

    2. Measure the depth of wear of the 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.

  12. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B003U0MC01
      *a Moves Smoothly
      *b Depth

      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 assembly.

  13. INSPECT CHAIN TENSIONER SLIPPER


    1. B003TXBC01
      *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.

  14. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. B003US0C01
      *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.

  15. INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. B003WKJC01
      *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.

  16. 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. B003TT7C02
        *a 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. B003W3KC02
        *a Plastigage
        *b No. 1 Journal
        *c No. 2 Journal
        *d No. 3 Journal
        *e No. 4 Journal
        *f No. 5 Journal

        Measure the Plastigage at its widest point.

        Standard Oil Clearance
        Item Specified Condition
        No. 1 Journal 0.040 to 0.063 mm (0.00157 to 0.00248 in.)
        No. 2, 3, 4 Journals 0.025 to 0.062 mm (0.00098 to 0.00244 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 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. B003UBKC02
        *a 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. B003VG1C02
        *a Plastigage
        *b No. 1 Journal
        *c Other Journals

        Measure the Plastigage at its widest point.

        Standard Oil Clearance
        Item Specified Condition
        No. 1 Journal 0.032 to 0.071 mm (0.00126 to 0.00280 in.)
        Other Journals 0.025 to 0.062 mm (0.00098 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 sub-assembly LH.

  17. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY


    1. B003T5ZC01
      *a for Bank 1
      *b for Bank 2

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

      Maximum warpage
      0.5 mm (0.0197 in.)

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

  18. INSPECT INTAKE MANIFOLD


    1. B003TI8C02
      *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.