ENGINE UNIT INSPECTION


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


    1. A01G55T

      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 of dirt and foreign matter.

    • Only use clean engine oil.


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

    2. A01G7QRE17
      Text in Illustration
      *1 Tapered Part
      *2 Plunger
      *3 Check Ball
      *a Correct
      *b Incorrect
      *c Low Pressure Chamber
      *d High Pressure Chamber

      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 CAMSHAFT


    1. Inspect the camshaft for runout.


      1. Place the camshaft on V-blocks.

      2. A01G5UJ

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

        Maximum runout
        0.04 mm (0.00157 in.)

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

        Tech Tips

        Check the oil clearance after replacing the camshaft.

    2. A01G672

      Using a micrometer, measure the cam lobe height.

      Standard Cam Lobe Height
      Item Specification
      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 Specification
      Intake camshaft 44.166 mm (1.7388 in.)
      Exhaust camshaft 44.112 mm (1.7366 in.)

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

    3. A01G8G3

      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 (1.0221 to 1.0226 in.)

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

  4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Clamp the camshaft in a vise.

      Note

      Be careful not to damage the camshaft in the vise.

    2. A01G7KPE09
      Text in Illustration
      *1 Straight Pin
      *a Key Groove

      Put the camshaft timing gear assembly and camshaft together by aligning the key groove and straight pin.

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

    4. A01G9KR

      Tighten the bolt while holding the camshaft.

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

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

    6. A01G5D8E12
      Text in Illustration
      *1 Advance Side Path
      *2 Retard Side Path
      *3 Vinyl Tape
      *4 Rubber
      *a Close
      *b 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 groove of the camshaft. Plug 2 paths with rubber piece.

      2. Break through the tape of the advance side path and the retard side path on the opposite side of the groove as shown in the illustration.

      3. A01G9B9E11
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path

        Apply approximately 200 kPa (2.0 kgf/cm2, 29 psi) of air pressure to the 2 opened paths (the advance side path and the retard side path).

        CAUTION:

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

      4. A01G7UZE13
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *a Hold Pressure
        *b 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

        The lock pin is released and the camshaft timing gear assembly turns in the advance direction.

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

        Note

        Be sure to release the air pressure from the retard side path first. If the air pressure of the advance side path is released first, the camshaft timing gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.

    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 in the most retarded position.

    9. A01G6DGE16
      Text in Illustration
      *1 Straight Pin
      *2 Bolt
      *a Do Not Remove

      Remove the 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. Clamp the camshaft in a vise.

      Note

      Be careful not to damage the camshaft in the vise.

    2. A01G7KPE09
      Text in Illustration
      *1 Straight Pin
      *a Key Groove

      Put the camshaft timing exhaust gear assembly and camshaft together by aligning the key groove and straight pin.

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

    4. A01G4MW

      Tighten the bolt while holding the camshaft.

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

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

    6. A01G6H5E09
      Text in Illustration
      *1 Retard Side Path
      *2 Advance Side Path
      *3 Rubber
      *4 Vinyl Tape
      *a Open
      *b Close

      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 groove of the camshaft. Plug 2 paths with rubber piece.

      2. Break through the tape of the advance side path and the retard side path on the opposite side of the groove as shown in the illustration.

      3. A01G8I4E07
        Text in Illustration
        *1 Advance Side Path
        *2 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 paths with a piece of cloth when applying pressure to prevent oil from spraying.

      4. A01G76NE10
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *a Decompress
        *b 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

        The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.

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

        Note

        Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.

    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 gear assembly automatically returns to the most advance 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 advance position.

    9. A01G4S9E07
      Text in Illustration
      *1 Straight Pin
      *2 Bolt
      *a Do Not Remove

      Remove the 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. A01G4N4E11
      Text in Illustration
      *a Measurement Point

      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. A01G949E11
      Text in Illustration
      *a Measuring Point

      Pull the chain sub-assembly with a force of 147 N (15 kgf, 33.1 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.)

      Note

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

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

  8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. A01G949E11
      Text in Illustration
      *a Measuring Point

      Pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33.1 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.)

      Note

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

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

  9. INSPECT CRANKSHAFT TIMING SPROCKET


    1. Place the chain around the crankshaft timing sprocket.

    2. A01G51Q

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

      Minimum sprocket diameter (with chain)
      61.4 mm (2.418 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 sprocket.

  10. INSPECT IDLE SPROCKET ASSEMBLY


    1. Place the chain around the idle sprocket assembly.

    2. A01G4GH

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

      Minimum sprocket diameter (with chain)
      61.4 mm (2.418 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 chain sub-assembly and idle sprocket assembly.

  11. INSPECT NO. 1 IDLE GEAR SHAFT OIL CLEARANCE


    1. A01G8KU

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

      Standard No. 1 idle gear shaft diameter
      22.987 to 23.000 mm (0.9050 to 0.9055 in.)
    2. A01G8N3

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

      Standard idle gear inside diameter
      23.020 to 23.030 mm (0.9063 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.)

      If the thrust oil clearance is greater than the maximum, replace the No. 1 idle gear shaft and idle sprocket assembly.

  12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01G4TNE07
      Text in Illustration
      *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


    1. A01G746E03
      Text in Illustration
      *a Depth

      Check that the plunger moves smoothly.

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

      Maximum depth
      0.9 mm (0.0354 in.)

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

  14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01G5RDE03
      Text in Illustration
      *a Depth

      Check that the plunger moves smoothly.

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

      Maximum depth
      0.9 mm (0.0354 in.)

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

  15. INSPECT CHAIN TENSIONER SLIPPER


    1. A01G6ZCE03
      Text in Illustration
      *a Depth

      Measure the worn depth of the chain tensioner slipper.

      Maximum depth
      1.0 mm (0.0394 in.)

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

  16. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. A01G5APE03
      Text in Illustration
      *a Depth

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

      Maximum depth
      1.0 mm (0.0394 in.)

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

  17. INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. A01G6UHE03
      Text in Illustration
      *a Depth

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

      Maximum depth
      1.0 mm (0.0394 in.)

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

  18. INSPECT CAMSHAFT THRUST CLEARANCE


    1. Inspect the bank 1 camshaft thrust clearance.


      1. Install the bank 1 camshaft Click here.

      2. A01G9Q1

        Using a dial indicator, measure the thrust clearance while moving the 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.)

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

    2. Inspect the bank 2 camshaft thrust clearance.


      1. Install the bank 2 camshaft Click here.

      2. Using a dial indicator, measure the thrust clearance while moving the 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.)

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

  19. INSPECT CAMSHAFT OIL CLEARANCE (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. A01G83TE05
      Text in Illustration
      *1 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. A01G78OE06
      Text in Illustration
      *1 Plastigage
      *2 No. 1 Journal
      *3 Other Journals

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      Item Oil Clearance
      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 Oil Clearance
      No. 1 journal 0.10 mm (0.00394 in.)
      Other journals 0.09 mm (0.00354 in.)

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

  20. INSPECT CAMSHAFT OIL CLEARANCE (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. A01G7LQE04
      Text in Illustration
      *1 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. A01G6B9E05
      Text in Illustration
      *1 Plastigage
      *2 No. 1 Journal
      *3 Other Journals

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      Item Oil Clearance
      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 Oil Clearance
      No. 1 journal 0.10 mm (0.00394 in.)
      Other journals 0.09 mm (0.00354 in.)

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

  21. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01G73O

      Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head sub-assembly LH.

      Maximum warpage
      0.7 mm (0.0276 in.)

      Tech Tips

      The maximum allowable warpage of each installation surface is 0.3 mm (0.0118 in.).

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

  22. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01G8KA

      Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head sub-assembly RH.

      Maximum warpage
      0.7 mm (0.0276 in.)

      Tech Tips

      The maximum allowable warpage of each installation surface is 0.3 mm (0.0118 in.).

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

  23. INSPECT INTAKE MANIFOLD

    A01G4WWE07
    Text in Illustration
    *a Cylinder Head Side
    *b Surge Tank Side

    1. Cylinder head side:


      1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head sub-assembly for warpage.

        Maximum warpage
        0.1 mm (0.00394 in.)
        If the warpage is greater than the maximum, replace the intake manifold.

    2. Surge tank side:


      1. Using a precision straightedge and feeler gauge, measure the surface contacting the surge tank for warpage.

        Maximum warpage
        0.1 mm (0.00394 in.)
        If the warpage is greater than the maximum, replace the intake manifold.