ENGINE UNIT INSPECTION

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

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

      A011TSS

      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.

    • Use only clean engine oil.

    A011TPGE02
    Text in Illustration
    *1 Plunger
    *2 Check Ball
    *a CORRECT
    *b INCORRECT
    *c Taper Part
    *d Low Pressure Chamber
    *e High Pressure Chamber

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

  3. INSPECT CAMSHAFT OIL CLEARANCE

    Note

    Do not turn the camshafts.

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

    2. Place the camshafts on the camshaft housing.

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

      A011TNAE04
      Text in Illustration
      *1 Plastigage

    4. Install the camshaft bearing caps Click here.

    5. Install the camshaft housing sub-assembly Click here.

    6. Remove the camshaft bearing caps Click here.

    7. Measure the Plastigage at its widest point.

      A011SW6E04
      Standard Oil Clearance
      Item Specified Condition
      Intake No. 1 journal 0.035 to 0.072 mm (0.00137 to 0.00283 in.)
      Exhaust No. 1 journal 0.049 to 0.086 mm (0.00193 to 0.00339 in.)
      Other journal 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
      Maximum Oil Clearance
      Item Specified Condition
      Intake No. 1 journal 0.085 mm (0.00335 in.)
      Exhaust No. 1 journal 0.095 mm (0.00374 in.)
      Other journal 0.085 mm (0.00335 in.)
      Text in Illustration
      *1 Plastigage
      *2 No. 1 Journal
      *3 Other Journal

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

  4. INSPECT CAMSHAFT THRUST CLEARANCE

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

    2. Place the camshafts on the camshaft housing.

    3. Install the camshaft bearing caps Click here.

    4. Install the camshaft housing sub-assembly Click here.

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

      A011TPN
      Standard Thrust Clearance
      Item Specified Condition
      Intake 0.060 to 0.155 mm (0.00236 to 0.00610 in.)
      Exhaust 0.060 to 0.155 mm (0.00236 to 0.00610 in.)
      Maximum Thrust Clearance
      Item Specified Condition
      Intake 0.170 mm (0.00669 in.)
      Exhaust 0.170 mm (0.00669 in.)

      If the thrust clearance is more than the maximum, replace the camshaft housing. If the thrust surface is damaged, replace the camshaft.

  5. INSPECT CAMSHAFT

    1. Inspect the camshaft runout.

      A011UAE

      1. Place the camshaft on V-blocks.

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

        Maximum runout
        0.03 mm (0.00118 in.)

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

        Tech Tips

        Check the oil clearance after replacing the camshaft.

    2. Inspect the cam lobes.

      A011TIB

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

        Standard Cam Lobe Height
        Item Specified Condition
        Intake 44.163 to 44.305 mm (1.739 to 1.744 in.)
        Exhaust 44.144 to 44.286 mm (1.738 to 1.744 in.)
        Minimum Cam Lobe Height
        Item Specified Condition
        Intake 44.013 mm (1.733 in.)
        Exhaust 43.996 mm (1.732 in.)

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

    3. Inspect the camshaft journals.

      A011TWZ

      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 22.959 to 22.975 mm (0.904 to 0.905 in.)

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

  6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    1. Fit the camshaft and camshaft timing gear assembly by aligning the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

      A011T73E02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

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

      A011SR5E11
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *2 Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

    3. While holding the camshaft, install the installation bolt of the camshaft timing gear assembly by hand.

      Note

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

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

      1. Make sure that the camshaft timing gear assembly is locked.

        Note

        Be careful not to damage the camshaft.

    5. Release the lock pin.

      A011UG2E05
      Text in Illustration
      *1 Rubber Piece
      *2 Vinyl Tape
      *3 Knock Pin
      *a Retard Side Path
      *b Advance Side Path
      *c Open
      *d Close

      1. Clean the camshaft journal with non-residue solvent.

      2. Cover the 4 oil paths of the camshaft journal with vinyl tape as shown in the illustration.

        Tech Tips

        There are 4 oil paths in the grooves of the camshaft. Plug 3 of the paths with rubber pieces.

      3. Prick a hole at port A shown in the illustration.

      4. While applying approximately 200 kPa (2.0 kgf/ cm2, 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        A011SO9

        CAUTION:

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

        Note

        Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

        Tech Tips

        • The camshaft timing gear assembly may be turned in the advance direction without applying any force.

        • If enough air pressure cannot be applied because of an air leak from the port, releasing the lock pin may be difficult.

    6. Check for smooth rotation.

      1. Turn the camshaft timing gear assembly within its movable range (19 to 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 allow the camshaft timing gear assembly to lock.

        If it locks, release the lock pin again.

    7. Remove the vinyl tape and rubber pieces from the camshaft.

    8. Remove the bolt and camshaft timing gear assembly.

  7. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    1. Fit the No. 2 camshaft and camshaft timing exhaust gear assembly by aligning the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

      A011RG6E05
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

    2. Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.

      A011SR5E11
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

    3. While holding the No. 2 camshaft, install the installation bolt of the camshaft timing exhaust gear assembly by hand.

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

      1. Make sure that the camshaft timing exhaust gear assembly is locked.

        Note

        Be careful not to damage the No. 2 camshaft.

    5. Release the lock pin.

      A011THXE03
      Text in Illustration
      *1 Vinyl Tape
      *2 Rubber Piece
      *3 Knock Pin
      *a Retard Side Path
      *b Advance Side Path
      *c Open
      *d Close

      1. Clean the No. 2 camshaft journal with non-residue solvent.

      2. Cover the 4 oil paths of the No. 2 camshaft journal with vinyl tape as shown in the illustration.

        Tech Tips

        There are 4 oil paths in the grooves of the camshaft. Plug 2 paths with rubber pieces.

      3. Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path, as shown in the illustration.

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

        A011VB8E05
        Text in Illustration
        *1 Retard Side Path
        *2 Advance Side Path

        Note

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

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

        A011UV2E04
        Text in Illustration
        *1 Retard Side Path
        *2 Advance Side Path
        *3 Hold Pressure
        *4 Decompress

        Tech Tips

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

      6. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure 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.

    6. Check for smooth rotation.

      1. Turn the camshaft timing exhaust gear assembly within its movable range (19 to 21°) 2 or 3 times, but do not turn it to the most advanced 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.

    7. Check the lock at the most advanced position.

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

    8. Remove the vinyl tape and rubber pieces from the No. 2 camshaft.

    9. Remove the bolt and camshaft timing exhaust gear assembly.

  8. INSPECT CHAIN SUB-ASSEMBLY

    A011U89E11
    Text in Illustration
    *a Measurement Area

    1. 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 pins.

      Maximum chain sub-assembly elongation
      137.7 mm (5.42 in.)

      Tech Tips

      Perform the measurement at 3 random places.

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

  9. INSPECT CRANKSHAFT TIMING SPROCKET

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

      A011SAX

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

      Minimum crankshaft timing sprocket diameter (with chain sub-assembly)
      59.94 mm (2.36 in.)

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

      Tech Tips

      The vernier caliper must contact the chain sub-assembly rollers for the measurement.

  10. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

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

      A011UU8

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

  11. INSPECT CHAIN TENSIONER SLIPPER

    1. Measure the wear depth of the chain tensioner slipper.

      A011USKE05
      Text in Illustration
      *a Depth
      Maximum depth
      1.0 mm (0.0394 in.)

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

  12. INSPECT NO. 1 CHAIN VIBRATION DAMPER

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

      A011TFJE05
      Text in Illustration
      *a Depth
      Maximum depth
      1.0 mm (0.0394 in.)

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

  13. INSPECT TIMING CHAIN GUIDE

    1. Measure the wear depth of the timing chain guide.

      A011RWWE05
      Text in Illustration
      *a Depth
      Maximum depth
      1.0 mm (0.0394 in.)

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

  14. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE

    1. Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.

      A011ST6
      Standard thrust clearance
      0.05 to 0.09 mm (0.00197 to 0.00354 in.)
      Maximum thrust clearance
      0.09 mm (0.00354 in.)

      If the thrust clearance is more than the maximum, replace the engine balancer assembly.

  15. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE

    1. Using a dial indicator, measure the thrust clearance while moving the No. 2 balance shaft back and forth.

      A011S8N
      Standard thrust clearance
      0.05 to 0.09 mm (0.00197 to 0.00354 in.)
      Maximum thrust clearance
      0.09 mm (0.00354 in.)

      If the thrust clearance is more than the maximum, replace the engine balancer assembly.

  16. INSPECT BALANCE SHAFT BACKLASH

    1. While holding the No. 2 balance shaft, measure the backlash of the No. 1 and No. 2 balance shafts using a dial indicator as shown in the illustration.

      A011UKME04
      Text in Illustration
      *a Hold
      Standard backlash
      0.04 to 0.17 mm (0.00157 to 0.00669 in.)
      Maximum backlash
      0.17 m (0.00669 in.)

      Note

      Measure at 3 or more points on the circumference of the No. 1 and No. 2 balance shafts.

      If the backlash is more than the maximum, replace the engine balancer assembly.

  17. INSPECT CYLINDER HEAD BOLT

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

      A011SGOE15
      Text in Illustration
      *a Measurement Point
      Standard diameter
      10.85 to 11.00 mm (0.427 to 0.433 in.)
      Minimum diameter
      10.6 mm (0.417 in.)
      Measurement point (distance from the seat)
      106 mm (4.17 in.)

      Tech Tips

      • If the diameter is less than the minimum, replace the cylinder head bolt. Failure to do so may lead to engine damage.

      • If there is any thread deformation, replace the cylinder head bolt with a new one.

  18. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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

      A011RCP
      Maximum warpage
      0.7 mm (0.0276 in.)

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