ENGINE UNIT INSPECTION

PROCEDURE


  1. INSPECT NO. 1 CHAIN SUB-ASSEMBLY


    1. B003Q7CC01
      *a Measuring Point

      Using a spring scale, pull the No. 1 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 16 pins.

      Maximum chain elongation
      144.7 mm (5.70 in.)

      Tech Tips

      Perform the measurement at 3 random places.

      If the elongation is more than the maximum, replace the No. 1 chain sub-assembly.

  2. INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. B003RAWC01
      *a Measuring Point

      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 16 pins.

      Maximum chain elongation
      121.6 mm (4.79 in.)

      Tech Tips

      Perform the measurement at 3 random places.

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

  3. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B003QDSC01
      *a Plunger

      Push the plunger and check that it moves smoothly.

      If necessary, replace the No. 1 chain tensioner assembly.

  4. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B003RGBC01
      *a Stopper Plate
      *b Plunger

      Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly.

      If necessary, replace the No. 2 chain tensioner assembly.

  5. INSPECT CAMSHAFT TIMING SPROCKET


    1. Wrap the No. 2 chain sub-assembly around the camshaft timing sprocket.

    2. B003JSA

      Using a vernier caliper, measure the camshaft timing sprocket diameter with the No. 2 chain sub-assembly.

      Minimum sprocket with chain diameter
      97.79 mm (3.85 in.)

      If the diameter is less than the minimum, replace the No. 2 chain sub-assembly and camshaft timing sprocket.

      Tech Tips

      The vernier caliper must contact the No. 2 chain sub-assembly rollers for the measurement.

  6. INSPECT CRANKSHAFT TIMING SPROCKET


    1. Wrap the No. 1 chain sub-assembly around the crankshaft timing sprocket.

    2. B003N6D

      Using a vernier caliper, measure the crankshaft timing sprocket diameter with the No. 1 chain sub-assembly.

      Minimum sprocket with chain diameter
      71.26 mm (2.81 in.)

      If the diameter is less than the minimum, replace the No. 1 chain sub-assembly and crankshaft timing sprocket.

      Tech Tips

      The vernier caliper must contact the No. 1 chain sub-assembly rollers for the measurement.

  7. INSPECT INJECTION PUMP DRIVE GEAR


    1. for No. 1 Chain Sub-assembly Side:


      1. Wrap the No. 1 chain sub-assembly around the injection pump drive gear.

      2. B003OMM

        Using a vernier caliper, measure the injection pump drive gear diameter with the No. 1 chain sub-assembly.

        Minimum gear with chain diameter
        71.26 mm (2.81 in.)

        If the diameter is less than the minimum, replace the No. 1 chain sub-assembly and injection pump drive gear.

        Tech Tips

        The vernier caliper must contact the No. 1 chain sub-assembly rollers for the measurement.

    2. for No. 2 Chain Sub-assembly Side:


      1. Wrap the No. 2 chain sub-assembly around the injection pump drive gear.

      2. B003K4W

        Using a vernier caliper, measure the injection pump drive gear diameter with the No. 2 chain sub-assembly.

        Minimum gear with chain diameter
        52.32 mm (2.06 in.)

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

        Tech Tips

        The vernier caliper must contact the No. 2 chain sub-assembly rollers for the measurement.

  8. INSPECT NO. 1 CHAIN TENSIONER SLIPPER


    1. B003NLCC01
      *a Depth

      Measure the depth of wear of the No. 1 chain tensioner slipper.

      Maximum depth
      1.0 mm (0.0394 in.)

      If the depth is more than the maximum, replace the No. 1 chain tensioner slipper.

  9. INSPECT NO. 2 CHAIN TENSIONER SLIPPER


    1. B003K31C01
      *a Depth

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

      Maximum depth
      1.0 mm (0.0394 in.)

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

  10. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. B003MR2C01
      *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.

  11. INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. B003RLYC01
      *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.

  12. INSPECT TIMING CHAIN GUIDE


    1. B003LKOC01
      *a Depth

      Measure the depth of wear of the timing chain guide.

      Maximum depth
      1.0 mm (0.0394 in.)

      If the depth is more than the maximum, replace the timing chain guide.

  13. INSPECT INTAKE MANIFOLD


    1. B003RF7

      Using a precision straightedge and feeler gauge, measure the warpage of the surface where the intake manifold contacts the cylinder head sub-assembly.

      Maximum warpage
      0.10 mm (0.00394 in.)

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

  14. INSPECT EXHAUST MANIFOLD


    1. B003JDT

      Using a precision straightedge and feeler gauge, measure the warpage of the surface where the exhaust manifold contacts the cylinder head sub-assembly.

      Maximum warpage
      0.10 mm (0.00394 in.)

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

  15. 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 circle runout is more than the maximum, replace the camshaft.

        Tech Tips

        Check the oil clearance after replacing the camshaft.

    2. Inspect the cam lobes.


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

        Standard cam lobe height
        41.425 to 41.525 mm (1.631 to 1.635 in.)
        Minimum cam lobe height
        41.375 mm (1.629 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
        Item Specified Condition
        No. 1 journal 34.449 to 34.465 mm (1.356 to 1.357 in.)
        Other journals 22.990 to 23.007 mm (0.905 to 0.906 in.)

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

  16. INSPECT NO. 2 CAMSHAFT


    1. Inspect the No. 2 camshaft 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
        0.03 mm (0.00118 in.)

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

        Tech Tips

        Check the oil clearance after replacing the No. 2 camshaft.

    2. Inspect the cam lobes.


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

        Standard cam lobe height
        41.694 to 41.794 mm (1.641 to 1.645 in.)
        Minimum cam lobe height
        41.644 mm (1.640 in.)

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

    3. Inspect the No. 2 camshaft journals.


      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter
        Item Specified Condition
        No. 1 journal 34.449 to 34.465 mm (1.356 to 1.357 in.)
        Other journals 22.990 to 23.007 mm (0.905 to 0.906 in.)

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

  17. INSPECT CAMSHAFT OIL CLEARANCE


    1. Clean the No. 1 camshaft bearing cap, No. 2 camshaft bearing caps, camshaft journals and No. 2 camshaft journals.

    2. Place the camshaft and No. 2 camshaft on the cylinder head sub-assembly.

    3. B003MDSC01
      *a Plastigage

      Lay a strip of Plastigage across each of the camshaft journals.

    4. Install the No. 1 camshaft bearing cap and No. 2 camshaft bearing caps to the cylinder head sub-assembly.

      Click here

      Note

      Do not turn the camshaft and No. 2 camshaft.

    5. Remove the No. 1 camshaft bearing cap and No. 2 camshaft bearing caps from the cylinder head sub-assembly.

      Click here

    6. B003KK4

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      Item Specified Condition
      No. 1 journal 0.040 to 0.077 mm (0.00157 to 0.00303 in.)
      Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
      Maximum Oil Clearance
      Item Specified Condition
      No. 1 journal 0.117 mm (0.00461 in.)
      Other journals 0.102 mm (0.00402 in.)

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

    7. Completely remove the Plastigage from the camshaft journals.

  18. INSPECT CYLINDER HEAD SET BOLT


    1. w/ Washer:


      1. B003OD6C01
        *a Measuring Area
        *b Washer

        Using a vernier caliper, measure the thread outside diameter of the cylinder head set bolt.

        Minimum diameter
        11.4 mm (0.449 in.)

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

    2. w/o Washer:


      1. B003N8FC01
        *a Measuring Area

        Using a vernier caliper, measure the thread outside diameter of the cylinder head set bolt.

        Minimum diameter
        12.8 mm (0.504 in.)

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

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


    1. Turn the roller by hand and check that it turns smoothly.

      If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.

  20. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the adjuster free from dirt and foreign matter.

    • Use only clean engine oil.


    1. Place the valve lash adjuster assembly into a container full of new engine oil.

      B003PXUC01
      *a CORRECT *b INCORRECT
      *c Taper Part *d Plunger
      *e Low Pressure Chamber *f Check Ball
      *g High Pressure Chamber - -

    2. 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 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 will not bleed.

    5. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers.

      OK
      Plunger is very difficult to move.

      If the result is not as specified, replace the valve lash adjuster assembly.