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ENGINE UNIT INSPECTION

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  1. Click here

    INSPECT CYLINDER HEAD SET BOLT


    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.)
      Table 1. Text in Illustration
      *1 Measurement Length

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

    2. A015DRI

      Using a vernier caliper, measure the diameter of the elongated thread at the narrowest visible area.

      Standard diameter
      10.73 to 10.97 mm (0.422 to 0.432 in.)
      Minimum diameter
      10.40 mm (0.409 in.)

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

      Tip:

      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.

  2. Click here

    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.

  3. Click here

    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. A0157K1E14

      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.

      09276-75010
      Table 2. Text in Illustration
      *1 Tapered Path
      *2 Plunger
      *3 Low Pressure Chamber
      *4 Check Ball
      *5 High Pressure Chamber
      *a CORRECT
      *b INCORRECT
    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.

  4. Click here

    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 runout
        0.04 mm (0.00157 in.)

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

        Tip:

        Check the oil clearance after replacing the camshaft.

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

      Standard Cam Lobe Height
      Item Specified Condition
      Intake 43.890 to 43.990 mm (1.728 to 1.732 in.)
      Exhaust 44.262 to 44.362 mm (1.743 to 1.747 in.)
      Minimum Cam Lobe Height
      Item Specified Condition
      Intake 43.840 mm (1.726 in.)
      Exhaust 44.212 mm (1.741 in.)
    3. 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.)

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

  5. Click here

    INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note:

      Be careful not to damage the camshaft.

    2. A0158R0E01

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

      Table 3. Text in Illustration
      *1 Pin Hole
      *2 Straight Pin
    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

      Note:

      Be sure not to turn the camshaft timing gear assembly in the retard direction.

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

    5. A015AUT

      Tighten the flange bolt while holding the camshaft.

      100 N*m 1020 kgf*cm 74 ft.*lbf
    6. Check the lock of the camshaft timing gear assembly.


      1. Fix the camshaft in place and confirm that the camshaft timing gear assembly is locked.

        Note:

        Be careful not to damage the camshaft.

    7. A0158WGE01

      Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Table 4. Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *3 Open
        *4 Close
        A0155U9 Rubber
        A015DBF Vinyl Tape
        Tip:

        The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece.

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

      3. A015DMKE01

        Apply air at approximately 200 kPa (2.0 kgf/cm2, 28 psi) to the 2 open paths.

        Table 5. Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        CAUTION:

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

      4. A015AK2E01

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

        Table 6. Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *3 Hold Pressure
        *4 Decompress
        Tip:

        This operation releases the lock pin at the most retarded position.

      5. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure first from the retard side path and next from the advance side path.

        Note:

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

    8. 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 gear turns smoothly.

        Note:

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

    9. Check the lock in the most retarded position.


      1. Confirm that the camshaft timing gear assembly locks at the most retarded position.

    10. A0159Z4E01

      Remove the flange bolt and camshaft timing gear assembly.

      Table 7. Text in Illustration
      *1 Do not remove
      *2 Straight Pin
      *3 Flange Bolt
      Note:
      • Do not remove the other 3 bolts.

      • If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear.

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    INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note:

      Be careful not to damage the camshaft.

    2. A0156L0E01

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

      Table 8. Text in Illustration
      *1 Pin Hole
      *2 Straight Pin
    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

      Note:

      Be sure not to turn the camshaft timing exhaust gear in the advanced direction.

    4. Check that there is no clearance between the gear flange and camshaft.

    5. A015DWN

      Tighten the flange bolt while holding the camshaft.

      100 N*m 1020 kgf*cm 74 ft.*lbf
    6. Check the camshaft timing exhaust gear lock.


      1. Make sure that the camshaft timing exhaust gear assembly locks.

    7. A0156ZNE01

      Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Table 9. Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *3 Open
        *4 Close
        A0155U9 Rubber
        A015DBF Vinyl Tape
        Tip:

        The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece.

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

      3. A015CUQE01

        Apply air at approximately 200 kPa (2.0 kgf/cm2, 28 psi) to the 2 open paths (the advance side path and retard side path).

        Table 10. Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        CAUTION:

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

      4. A015CTOE01

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

        Table 11. Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *3 Hold Pressure
        *4 Decompress
        Tip:

        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.

    8. 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 advanced position. Make sure that the 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 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.

    9. Check the lock at the most advanced position.


      1. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position.

    10. A0155DVE01

      Remove the flange bolt and camshaft timing exhaust gear assembly.

      Table 12. Text in Illustration
      *1 Do not remove
      *2 Straight Pin
      *3 Flange Bolt
      Note:
      • Be sure not to remove the other 4 bolts.

      • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

  7. Click here

    INSPECT CHAIN SUB-ASSEMBLY


    1. A015CKWE11

      Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33 lbf) and measure the length of the chain using a vernier caliper.

      Maximum chain elongation
      136.9 mm (5.39 in.)
      Table 13. Text in Illustration
      *1 Measurement Area
      Tip:

      Perform the measurement at 3 random places.

      If a measurement is more than the maximum, replace the chain sub-assembly.

  8. Click here

    INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. Using a spring scale, pull the No. 2 chain 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.)
      Tip:

      Perform the measurement at 3 random places.

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

  9. Click here

    INSPECT CRANKSHAFT TIMING SPROCKET


    1. A015ACO

      Wrap the chain around the sprocket.

    2. Using a vernier caliper, measure the crankshaft timing sprocket diameter with the chain.

      Minimum gear diameter (with chain)
      61.0 mm (2.40 in.)
      Tip:

      The vernier caliper must contact the chain rollers for the measurement.

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

  10. Click here

    INSPECT NO. 1 IDLE GEAR


    1. A015CZ7

      Wrap the chain around the gear.

    2. Using a vernier caliper, measure the No. 1 idle gear diameter with the chain.

      Minimum gear diameter (with chain)
      61.0 mm (2.40 in.)
      Tip:

      The vernier caliper must contact the chain rollers for the measurement.

      If the diameter is less than the minimum, replace the chain and No. 1 idle gear.

  11. Click here

    INSPECT NO. 1 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 gear.

      Standard idle gear inside diameter
      23.02 to 23.03 mm (0.906 to 0.907 in.)
    3. Subtract the idle gear shaft diameter measurement from the idle gear 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 shaft oil clearance is more than the maximum, replace the idle gear shaft and idle gear.

  12. Click here

    INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A015DT1E03

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

      Table 14. Text in Illustration
      *1 Plunger
      *2 Stopper Plate
      *a Moves Smoothly

      If necessary, replace the No. 1 chain tensioner.

  13. Click here

    INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A015BG1E07

      Check that the plunger moves smoothly.

      Table 15. Text in Illustration
      *1 Depth
      *a Moves Smoothly
    2. Measure the depth of wear of the chain tensioner.

      Maximum depth
      1.0 mm (0.0394 in.)

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

  14. Click here

    INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A015D0ZE07

      Check that the plunger moves smoothly.

      Table 16. Text in Illustration
      *1 Depth
      *a Moves Smoothly
    2. Measure the depth of wear of the chain tensioner.

      Maximum depth
      1.0 mm (0.0394 in.)

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

  15. Click here

    INSPECT CHAIN TENSIONER SLIPPER


    1. A015CXUE05

      Measure the depth of wear of the chain tensioner slipper.

      Maximum depth
      1.0 mm (0.0394 in.)
      Table 17. Text in Illustration
      *1 Depth

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

  16. Click here

    INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. A015AICE05

      Measure the depth of wear of the No. 1 chain vibration damper.

      Maximum depth
      1.0 mm (0.0394 in.)
      Table 18. Text in Illustration
      *1 Depth

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

  17. Click here

    INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. A015DMUE03

      Measure the depth of wear of the No. 2 chain vibration damper.

      Maximum depth
      1.0 mm (0.0394 in.)
      Table 19. Text in Illustration
      *1 Depth

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

  18. Click here

    INSPECT CAMSHAFT THRUST CLEARANCE


    1. A015E81

      Install the camshafts (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 more than the maximum, replace the camshaft housing sub-assembly.

      If the thrust surface is damaged, replace the camshaft.

  19. Click here

    INSPECT CAMSHAFT OIL CLEARANCE


    1. Clean the camshaft bearing caps, camshaft housing and camshaft journals.

    2. Place the camshafts on the camshaft housing.

    3. A015AA5E04

      Lay a strip of Plastigage across each camshaft journal.

      Table 20. Text in Illustration
      *1 Plastigage
    4. Install the camshaft bearing caps (Click here).

      Note:

      Do not turn the camshaft.

    5. Remove the camshaft bearing caps (Click here).

    6. A0155L6E01

      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.)
      Table 21. Text in Illustration
      *1 Plastigage
      *2 No. 1 Journal
      *3 Other Journals

      If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the camshaft housing.

  20. Click here

    INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY


    1. A0155AL

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

      Maximum warpage
      0.70 mm (0.0276 in.)

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

  21. Click here

    INSPECT INTAKE MANIFOLD FOR FLATNESS


    1. A0156SME03

      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
      Item Specified Condition
      Intake air surge tank side 0.80 mm (0.0315 in.)
      Cylinder head side 0.20 mm (0.00787 in.)
      Table 22. Text in Illustration
      *a Intake Air Surge Tank Side
      *b Cylinder Head Side

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