ENGINE UNIT INSPECTION

PROCEDURE


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


    1. B006NTN

      Turn the roller by hand to check that it turns smoothly.

      Tech Tips

      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.

    • Only use clean engine oil.


    1. Place the valve lash adjuster assembly into a container filled with engine oil.

    2. B006LB1C08
      *a Tapered Path
      *b Plunger
      *c Check Ball
      *d Correct
      *e Incorrect
      *f Low Pressure Chamber
      *g High Pressure Chamber

      Insert the tip of SST into the 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 any air.

      OK
      Plunger moves up and down.

      Note

      When bleeding the air from the high-pressure chamber, make sure that the tip of SST is pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

    5. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger by hand.

      OK
      Plunger is very difficult to move.

      Tech Tips

      If the plunger is easy to move, replace the valve lash adjuster assembly.

  3. INSPECT CAMSHAFT


    1. Inspect the camshaft for runout.


      1. Place the camshaft on V-blocks.

      2. B006M5X

        Using a dial indicator, measure the runout at the center journal.

        Maximum Runout
        0.04 mm (0.00157 in.)

        Tech Tips


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

        • Check the oil clearance after replacing the camshaft.

    2. B006LOM

      Using a micrometer, measure the cam lobe height.

      Standard Cam Lobe Height
      Item Specified Condition
      Intake camshaft 44.316 to 44.416 mm (1.7448 to 1.7486 in.)
      Exhaust camshaft 44.262 to 44.362 mm (1.7426 to 1.7465 in.)
      Minimum Cam Lobe Height
      Item Specified Condition
      Intake camshaft 44.166 mm (1.7388 in.)
      Exhaust camshaft 44.112 mm (1.7366 in.)

      Tech Tips

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

    3. B006R44

      Using a micrometer, measure the journal diameter.

      Standard Journal Diameter
      Item Specified Condition
      No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
      Other journals 25.959 to 25.975 mm (1.0221 to 1.0226 in.)

      Tech Tips

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

  4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. B006MYLC01
      *a Hexagonal Portion

      Using SST, grip the hexagonal portion, and then secure the SST and camshaft in a vise as shown in the illustration and check that the camshaft timing gear assembly does not rotate.

      SST
      09212-31010

      Note


      • Do not damage the camshaft.

      • Never grip areas other than the hexagonal portion, as this may cause damage.

    2. B006R7JC01
      *a Knock Pin
      *b Pin Hole

      Align and fit the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

    3. Check that there is no gap between the camshaft timing gear assembly flange and the camshaft.

    4. While securely holding the camshaft, install the bolt of the camshaft timing gear assembly by hand.

      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

      Note

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

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

    6. B006O75C07
      *a Advance Side Path
      *b Retard Side Path
      *c Vinyl Tape
      *d Rubber Piece
      *e Closed
      *f Open

      Release the lock pin.


      1. 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 2 oil paths with rubber pieces.

      2. Make a hole in the vinyl tape on the advance side path and the retard side path on the opposite side of the groove as shown in the illustration.

      3. B006OHPC07
        *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 the retard side path).

        CAUTION:

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

      4. B006P0GC07
        *a Advance Side Path
        *b Retard Side Path
        *c Hold pressure
        *d Decompress

        Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path.

        Tech Tips

        This operation releases the lock pin and rotates the camshaft timing gear assembly in the advance direction.

      5. When the camshaft timing gear assembly moves to the most advanced position, release the air pressure from the retard side path, and then from the advance side path.

        Note

        Do not release the air pressure from the advance side path first. The camshaft timing gear assembly may abruptly shift in the retard direction and break the lock pin.

    7. Check for smooth rotation.


      1. Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the camshaft timing gear assembly turns smoothly.

        Note

        Do not use air pressure to perform the smooth operation check.

    8. Check the lock at the most retarded position.

    9. B006N79C01
      *a Knock Pin
      *b Bolt
      *c Do not remove

      Remove the bolt and camshaft timing gear assembly.

      Note

      Do not remove the other 3 bolts.

  5. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B006MYLC01
      *a Hexagonal Portion

      Using SST, grip the hexagonal portion, and then secure the SST and camshaft in a vise as shown in the illustration.

      SST
      09212-31010

      Note


      • Do not damage the camshaft.

      • Never grip areas other than the hexagonal portion, as this may cause damage.

    2. B006R7JC01
      *a Knock Pin
      *b Pin Hole

      Align and fit the knock pin of the camshaft with the pin hole of the camshaft timing exhaust gear assembly.

    3. Check that there is no gap between the camshaft timing exhaust gear assembly flange and the camshaft.

    4. While securely holding the camshaft, install the bolt of the camshaft timing exhaust gear assembly by hand.

      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

      Note

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    5. Check the lock of the camshaft timing exhaust gear assembly.

    6. B006OWSC08
      *a Retard Side Path
      *b Advance Side Path
      *c Rubber Piece
      *d Vinyl Tape
      *e Open
      *f Closed

      Release the lock pin.


      1. 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 2 oil paths with rubber pieces.

      2. Make a hole in the vinyl tape on the advance side path and the retard side path on the opposite side of the groove as shown in the illustration.

      3. B006LCEC07
        *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 the retard side path).

        CAUTION:

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

      4. B006KRXC07
        *a Advance Side Path
        *b Retard Side Path
        *c Decompress
        *d Hold pressure

        Check that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path.

        Tech Tips

        This operation releases the lock pin and rotates the camshaft timing exhaust gear assembly in the retard direction.

      5. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure from the advance side path, and then from the retard side path.

        Note

        Do not release the air pressure from the retard side path first. The camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin.

    7. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advance position. Make sure that the camshaft timing exhaust gear assembly turns smoothly.

        Note

        When the air pressure is released from the advance side path and then from the retard side path, the camshaft timing exhaust gear assembly 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.

    8. Check the lock at the most advanced position.

    9. B006R5VC01
      *a Knock Pin
      *b Bolt
      *c Do not remove

      Remove the bolt and camshaft timing exhaust gear assembly.

      Note

      Do not remove the other 4 bolts.

  6. INSPECT CYLINDER HEAD SET BOLT


    1. B006L9GC05
      *a Measurement Point
      *b 103 mm (4.06 in.)

      Using a vernier caliper, measure the diameter of the threads at the measurement point.

      Standard Diameter
      10.85 to 11.00 mm (0.4272 to 0.4330 in.)
      Minimum Diameter
      10.70 mm (0.4212 in.)
      Measurement Point (Distance from the Seat)
      103 mm (4.06 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.

  7. INSPECT CHAIN SUB-ASSEMBLY


    1. B006REEC01
      *a Measurement Length

      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 links.

      Maximum Chain Elongation
      136.9 mm (5.389 in.)

      Tech Tips


      • 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.

  8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. B006REEC01
      *a Measurement Length

      Using a spring scale, pull the No. 2 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
      137.6 mm (5.417 in.)

      Tech Tips


      • 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.

  9. INSPECT CRANKSHAFT TIMING SPROCKET


    1. Place the chain sub-assembly around the crankshaft timing sprocket.

    2. B006QA8

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

      Minimum Sprocket Diameter (with Chain Sub-assembly)
      61.4 mm (2.418 in.)

      Tech Tips


      • The vernier caliper must contact the chain rollers when measuring.

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

  10. INSPECT IDLE SPROCKET ASSEMBLY


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

    2. B006R09

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

      Minimum Sprocket Diameter (with Chain Sub-assembly)
      61.4 mm (2.418 in.)

      Tech Tips


      • The vernier caliper must contact the chain rollers when measuring.

      • If the diameter is less than the minimum, replace the chain sub-assembly and idle sprocket assembly.

  11. INSPECT NO. 1 IDLE GEAR SHAFT OIL CLEARANCE


    1. B006L5N

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

      Standard No. 1 Idle Gear Shaft Diameter
      22.987 to 23.000 mm (0.9050 to 0.9055 in.)
    2. B006NOM

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

      Standard Idle Sprocket Assembly Inside Diameter
      23.020 to 23.030 mm (0.9063 to 0.9067 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 (0.000787 to 0.00169 in.)
      Maximum Oil Clearance
      0.093 mm (0.00366 in.)

      Tech Tips

      If the 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. B006QXIC01
      *a Plunger
      *b Stopper Plate

      Turn the stopper plate clockwise to release the lock. Push the plunger and check that it moves smoothly.

      Tech Tips

      If the plunger does not move smoothly, replace the No. 1 chain tensioner assembly.

  13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B006L37C01
      *a Depth

      Check that the plunger moves smoothly.

    2. Using a vernier caliper, measure the wear depth of the No. 2 chain tensioner assembly.

      Maximum Depth
      0.9 mm (0.0354 in.)

      Tech Tips

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

  14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B006M3DC01
      *a Depth

      Check that the plunger moves smoothly.

    2. Using a vernier caliper, measure the wear depth of the No. 3 chain tensioner assembly.

      Maximum Depth
      0.9 mm (0.0354 in.)

      Tech Tips

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

  15. INSPECT CHAIN TENSIONER SLIPPER


    1. B006MC4C04
      *a Depth

      Measure the wear depth of the chain tensioner slipper.

      Maximum Depth
      1.0 mm (0.0394 in.)

      Tech Tips

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

  16. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. B006NZDC04
      *a Depth

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

      Maximum Depth
      1.0 mm (0.0394 in.)

      Tech Tips

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

  17. INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. B006KUBC04
      *a Depth

      Using a vernier caliper, measure the wear depth of the No. 2 chain vibration damper.

      Maximum Depth
      1.0 mm (0.0394 in.)

      Tech Tips

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

  18. INSPECT CAMSHAFT THRUST CLEARANCE


    1. Inspect the camshaft thrust clearance (for Bank 1).


      1. Install the camshafts.

        Click here

      2. B006LW6

        Using a dial indicator, measure the thrust clearance while moving each camshaft back and forth.

        Standard Thrust Clearance
        0.08 to 0.13 mm (0.00315 to 0.00512 in.)
        Maximum Thrust Clearance
        0.15 mm (0.00591 in.)

        Tech Tips

        If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly RH. If the thrust surface is damaged, replace the camshaft.

    2. Inspect the camshaft thrust clearance (for Bank 2).


      1. Install the camshafts.

        Click here

      2. Using a dial indicator, measure the thrust clearance while moving each camshaft back and forth.

        Standard Thrust Clearance
        0.08 to 0.13 mm (0.00315 to 0.00512 in.)
        Maximum Thrust Clearance
        0.15 mm (0.00591 in.)

        Tech Tips

        If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly LH. If the thrust surface is damaged, replace the camshaft.

  19. 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 onto the camshaft housing sub-assembly RH.

      3. B006MO5C06
        *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. B006O3AC04
        *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 0.063 mm (0.00126 to 0.00248 in.)
        Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
        Maximum Oil Clearance
        Item Specified Condition
        No. 1 journal 0.10 mm (0.00394 in.)
        Other journals 0.09 mm (0.00354 in.)

        Tech Tips

        If the oil clearance is more than the maximum, replace the camshaft. If necessary, 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. B006OUEC05
        *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. B006MFIC03
        *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 0.063 mm (0.00126 to 0.00248 in.)
        Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
        Maximum Oil Clearance
        Item Specified Condition
        No. 1 journal 0.10 mm (0.00394 in.)
        Other journals 0.09 mm (0.00354 in.)

        Tech Tips

        If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the camshaft housing sub-assembly LH.

  20. INSPECT INTAKE MANIFOLD

    B006P2GC01
    *a Cylinder Head Side
    *b Surge Tank Side

    1. Cylinder head side:


      1. Using a precision straightedge and feeler gauge, check the surface which contacts the cylinder head sub-assembly for warpage.

        Maximum Warpage
        0.1 mm (0.00394 in.)

        Tech Tips

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

    2. Surge tank side:


      1. Using a precision straightedge and feeler gauge, check the surface which contacts the surge tank for warpage.

        Maximum Warpage
        0.1 mm (0.00394 in.)

        Tech Tips

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

  21. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY


    1. B006MJK

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

      Maximum Warpage
      0.7 mm (0.0276 in.)

      Tech Tips

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