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 from dirt and foreign matter.

    • Only use clean engine oil.

    A001UM9C19
    *a Correct *b Incorrect
    *c Taper *d Low Pressure Chamber
    *e High Pressure Chamber *f Plunger
    *g Check Ball - -

    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

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

      OK
      Plunger is very difficult to move.

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

  3. INSPECT CHAIN SUB-ASSEMBLY


    1. A001WMIC05
      *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
      115.2 mm (4.54 in.)

      Note

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

      Tech Tips

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

  4. INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. A001WMIC05
      *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
      102.1 mm (4.02 in.)

      Note

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

      Tech Tips

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

  5. INSPECT OIL PUMP DRIVE GEAR


    1. A001X5R

      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 No. 2 Chain Sub-assembly)
      48.2 mm (1.90 in.)

      Note

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

      Tech Tips

      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. A001UU6

      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 No. 2 Chain Sub-assembly)
      48.2 mm (1.90 in.)

      Note

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

      Tech Tips

      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. A001WCE

      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 Sub-assembly)
      96.8 mm (3.81 in.)

      Note

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

      Tech Tips

      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. A001SOX

      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 Sub-assembly)
      96.8 mm (3.81 in.)

      Note

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

      Tech Tips

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

  9. INSPECT CRANKSHAFT TIMING SPROCKET


    1. A001X5R

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

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

      Minimum Gear Diameter (with Chain Sub-assembly)
      51.1 mm (2.01 in.)

      Note

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

      Tech Tips

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

  10. INSPECT CHAIN TENSIONER SLIPPER


    1. A001VM1C05
      *a Depth

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

      Maximum Depth
      1.0 mm (0.0394 in.)

      Tech Tips

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

  11. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. A001V2BC02
      *a Depth

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

      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.

  12. INSPECT CHAIN TENSIONER PLATE


    1. A001YDDC05
      *a Depth

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

      Maximum Depth
      1.0 mm (0.0394 in.)

      Tech Tips

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

  13. INSPECT NO. 1 CHAIN TENSIONER


    1. A001XN1C04
      *a Raise
      *b Move
      *c Lock

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

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

      Tech Tips

      If necessary, replace the No. 1 chain tensioner.

  14. INSPECT CYLINDER HEAD SET BOLT


    1. A001TZDC14
      *a Measurement Length
      *b Measuring Area
      *c 115 mm (4.53 in.)

      Using a vernier caliper, measure the length of the cylinder head set 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.)

      Note


      • If the length is greater than the maximum, replace the cylinder head set bolt with a new one. 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.

    2. Using a vernier caliper, measure the diameter of the threads at several points within the area shown in the illustration.

      Standard Diameter
      9.77 to 9.96 mm (0.3846 to 0.3921 in.)
      Minimum Diameter
      9.4 mm (0.3701 in.)

      Note


      • Diameter measurements should be done at several points.

      • If the diameter is less than the minimum, replace the cylinder head set bolt with a new one. 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.

  15. INSPECT EXHAUST MANIFOLD


    1. A001U5U

      Using a precision straightedge and feeler gauge, measure the warpage on the surface that contacts the cylinder head sub-assembly.

      Maximum Warpage
      0.7 mm (0.0276 in.)

      Tech Tips

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