ENGINE UNIT INSPECTION

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

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

      A011UPT

      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 objects.

    • Only use clean engine oil.

    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.

      A011T7UE17
      Text in Illustration
      *1 Tapered Part
      *2 Plunger
      *3 Check Ball
      *a CORRECT
      *b INCORRECT
      *c Low Pressure Chamber
      *d High Pressure Chamber
      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. Using a dial indicator, measure the circle runout at the center journal.

        A011UQ3
        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. Using a micrometer, measure the cam lobe height.

      A011TJ6
      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. Using a micrometer, measure the journal diameter.

      A011SMF
      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. Put the camshaft timing gear assembly and camshaft together by aligning the key groove and straight pin.

      A011T0CE09
      Text in Illustration
      *1 Straight Pin
      *a Key Groove

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

    4. Tighten the flange bolt while holding the camshaft.

      A011UFF
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

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

      1. Clamp the camshaft in a vise, and confirm that the camshaft timing gear assembly is locked.

        Note

        Be careful not to damage the camshaft.

    6. Release the lock pin.

      A011U60E12
      Text in Illustration
      *1 Advance Side Path
      *2 Retard Side Path
      *3 Vinyl Tape
      *4 Rubber
      *a Close
      *b Open

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

        Tech Tips

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

        A011RRSE11
        Text in Illustration
        *1 Advanced Side Path
        *2 Retard Side Path

        CAUTION:

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

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

        A011RM4E13
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *a Hold Pressure
        *b Decompress

        Tech Tips

        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.

    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 gear turns smoothly.

        Note

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

    8. Check the lock in the most retarded position.

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

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

      A011UTTE11
      Text in Illustration
      *1 Straight Pin
      *2 Flange Bolt
      *a Do Not Remove

      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.

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

      A011T0CE09
      Text in Illustration
      *1 Straight Pin
      *a Key Groove

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

    4. Tighten the flange bolt while holding the camshaft.

      A011TWC
      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    5. Check the camshaft timing exhaust gear lock.

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

    6. Release the lock pin.

      A011VB7E09
      Text in Illustration
      *1 Retard Side Path
      *2 Advance Side Path
      *3 Rubber
      *4 Vinyl Tape
      *a Open
      *b Close

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

        Tech Tips

        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. 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).

        A011TBHE07
        Text in Illustration
        *1 Advanced Side Path
        *2 Retard Side Path

        CAUTION:

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

      4. 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.

        A011TP4E10
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *a Decompress
        *b Hold Pressure

        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 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.

    8. Check the lock at the most advanced position.

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

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

      A011V8VE07
      Text in Illustration
      *1 Straight Pin
      *2 Flange Bolt
      *a Do Not Remove

      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.

  6. INSPECT CYLINDER HEAD SET BOLT

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

      A011UYTE11
      Text in Illustration
      *a 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 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.

  7. INSPECT CHAIN SUB-ASSEMBLY

    1. Pull the chain sub-assembly with a force of 147 N (15 kgf, 33.1 lbf) as shown in the illustration.

      A011U89E11

    2. Using a vernier caliper, measure the length of 15 links.

      Text in Illustration
      *a Measuring Point
      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. Pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33.1 lbf) as shown in the illustration.

      A011U89E11

    2. Using a vernier caliper, measure the length of 15 links.

      Text in Illustration
      *a Measuring Point
      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 sprocket.

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

      A011R7M
      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 and sprocket.

  10. INSPECT IDLE SPROCKET ASSEMBLY

    1. Place the chain around the sprocket.

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

      A011SYX
      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 and sprocket.

  11. INSPECT IDLE GEAR SHAFT OIL CLEARANCE

    1. Using a micrometer, measure the idle gear shaft diameter.

      A011TF7
      Standard idle gear shaft diameter
      22.987 to 23.000 mm (0.9050 to 0.9055 in.)

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

      A011U0S
      Standard idle gear inside diameter
      23.020 to 23.030 mm (0.9063 to 0.9067 in.)

    3. Subtract the idle gear shaft diameter measurement from the idle sprocket 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 idle gear shaft and idle sprocket assembly.

  12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

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

      A011R89E07
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

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

  13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

    1. Check that the plunger moves smoothly.

      A011TPDE03
      Text in Illustration
      *a Depth

    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. Check that the plunger moves smoothly.

      A011SCNE03
      Text in Illustration
      *a Depth

    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. Measure the worn depth of the chain tensioner slipper.

      A011SPCE03
      Text in Illustration
      *a Depth
      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. Using a vernier caliper, measure the worn depth of the No. 1 chain vibration damper.

      A011SODE03
      Text in Illustration
      *a Depth
      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. Using a vernier caliper, measure the worn depth of the No. 2 chain vibration damper.

      A011S91E03
      Text in Illustration
      *a Depth
      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. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

        A011S9L
        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 cylinder head. 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 cylinder head. 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 and camshaft journals.

    2. Place the camshafts on the camshaft housing.

    3. Lay a strip of Plastigage across each camshaft journal.

      A011RAVE05
      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. Measure the Plastigage at its widest point.

      A011TXIE06
      Text in Illustration
      *1 Plastigage
      *2 No. 1 Journal
      *3 Other Journals
      Standard Oil Clearance
      Item Oil Clearance
      No. 1 journal 0.032 to 0.071 mm (0.00126 to 0.00280 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.

  20. INSPECT CAMSHAFT OIL CLEARANCE (for Bank 2)

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

    2. Place the camshafts on the camshaft housing.

    3. Lay a strip of Plastigage across each camshaft journal.

      A011RFYE04
      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. Measure the Plastigage at its widest point.

      A011S7YE05
      Text in Illustration
      *1 Plastigage
      *2 No. 1 Journal
      *3 Other Journals
      Standard Oil Clearance
      Item Oil Clearance
      No. 1 journal 0.032 to 0.071 mm (0.00126 to 0.00280 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.

  21. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH

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

      A011S3Y
      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 manifold.

  22. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH

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

      A011UB0
      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 manifold.

  23. INSPECT INTAKE MANIFOLD

    A011SQXE07
    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 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.