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.

      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.

      SST
      09276-75010
      B0076TXC07
      *a Correct *b Incorrect
      *c Tapered Path *d Plunger
      *e Low Pressure Chamber *f Check Ball
      *g High Pressure Chamber - -

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

      OK
      Plunger is very difficult to move.

      Tech Tips

      If the plunger can still be compressed after bleeding air 3 times, replace the valve lash adjuster assembly with a new one.

  3. INSPECT CAMSHAFT


    1. Inspect the camshaft for runout.


      1. Place the camshaft on V-blocks.

      2. B0075MD

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

        Maximum Runout
        0.04 mm (0.00157 in.)

        Tech Tips


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

        • Check the oil clearance after replacing the camshaft.

          Click here

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

      Standard Cam Lobe Height
      Item Specified Condition
      Intake 44.318 to 44.418 mm (1.7448 to 1.7487 in.)
      Exhaust 44.341 to 44.441 mm (1.7457 to 1.7496 in.)
      Exhaust (for Fuel Pump) 56.450 to 56.550 mm (2.2224 to 2.2264 in.)
      Minimum Cam Lobe Height
      Item Specified Condition
      Intake 44.168 mm (1.7389 in.)
      Exhaust 44.191 mm (1.7398 in.)
      Exhaust (for Fuel Pump) 56.300 mm (2.2165 in.)

    3. 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 (1.0220 to 1.0226 in.)

      Tech Tips

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

      Click here

  4. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  5. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  6. INSPECT CYLINDER HEAD SET BOLT

    Click here

  7. INSPECT CHAIN SUB-ASSEMBLY


    1. B00747TC02
      *a Measurement Area

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

      Maximum Chain Elongation
      136.9 mm (5.39 in.)

      Tech Tips

      Perform the measurement at 3 random places. If the elongation is more than the maximum, replace the chain sub-assembly.

  8. INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. B00747TC02
      *a Measurement Area

      Using a spring scale, pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) and measure the length of the No. 2 chain sub-assembly using a vernier caliper.

      Maximum Chain Elongation
      137.6 mm (5.42 in.)

      Tech Tips

      Perform the measurement at 3 random places. If the elongation is more than the maximum, replace the No. 2 chain sub-assembly.

  9. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET


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

    2. B0072O4

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

      Minimum Sprocket Diameter (with Chain Sub-assembly)
      61.4 mm (2.42 in.)

      Tech Tips


      • The vernier caliper must contact the chain rollers when measuring.

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

  10. INSPECT IDLE SPROCKET ASSEMBLY


    1. Place the chain sub-assembly around the idle sprocket assembly.

    2. B0073WL

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

      Minimum Sprocket Diameter (with Chain Sub-assembly)
      61.4 mm (2.42 in.)

      Tech Tips


      • The vernier caliper must contact the chain rollers when measuring.

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

  11. INSPECT IDLE GEAR SHAFT OIL CLEARANCE


    1. B0074RN

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

      Standard Diameter
      22.987 to 23.000 mm (0.905 to 0.906 in.)
    2. B00769P

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

      Standard Diameter
      23.020 to 23.030 mm (0.906 to 0.907 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 (0.00079 to 0.00169 in.)
      Maximum Oil Clearance
      0.093 mm (0.00366 in.)

      Tech Tips

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

  12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B0075CCC07
      *a Moves Smoothly
      *b Plunger
      *c Stopper Plate

      Turn the stopper plate clockwise to release the lock. Push the plunger and check that it moves smoothly.

      Tech Tips

      If the plunger does not move smoothly, replace the No. 1 chain tensioner assembly.

  13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

    B0075H8C02
    *a Depth
    *b Moves smoothly

    1. Check that the plunger moves smoothly.

    2. Measure the depth of wear of the No. 2 chain tensioner assembly.

      Maximum Depth
      0.9 mm (0.0354 in.)

      Tech Tips

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

  14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY

    B0077VNC02
    *a Depth
    *b Moves smoothly

    1. Check that the plunger moves smoothly.

    2. Measure the depth of wear of the No. 3 chain tensioner assembly.

      Maximum Depth
      0.9 mm (0.0354 in.)

      Tech Tips

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

  15. INSPECT CHAIN TENSIONER SLIPPER


    1. B0075OQC03
      *a Depth

      Measure the depth of wear of the chain tensioner slipper.

      Maximum Depth
      1.0 mm (0.0394 in.)

      Tech Tips

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

  16. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. B0072N8C03
      *a Depth

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

      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.

  17. INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. B0073OMC03
      *a Depth

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

      Maximum Depth
      1.0 mm (0.0394 in.)

      Tech Tips

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

  18. INSPECT CAMSHAFT OIL CLEARANCE


    1. 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. B0076Q6C11
        *a Plastigage

        Lay a strip of Plastigage across each camshaft journal.

      4. Install the camshaft bearing caps.

        Note

        Do not turn the camshafts.

        Click here

      5. Remove the camshaft bearing caps.

        Click here

      6. B0073YWC08
        *a Intake Side
        *b Exhaust Side
        *c Plastigage
        *d No. 1 Journal
        *e Other Journals

        Measure the Plastigage at its widest point.

        Standard Oil Clearance
        Item Specified Condition
        Exhaust side No. 1 journal 0.031 to 0.078 mm (0.00122 to 0.00307 in.)
        Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.)
        Maximum Oil Clearance
        Item Specified Condition
        Exhaust side No. 1 journal 0.10 mm (0.00394 in.)
        Other journals 0.09 mm (0.00354 in.)

        Tech Tips


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

        • If the oil clearance is still more than the maximum after replacing the camshaft, replace the camshaft housing sub-assembly RH.

    2. 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. B0076IKC11
        *a Plastigage

        Lay a strip of Plastigage across each camshaft journal.

      4. Install the camshaft bearing caps.

        Note

        Do not turn the camshafts.

        Click here

      5. Remove the camshaft bearing caps.

        Click here

      6. B0077BVC08
        *a Intake Side
        *b Exhaust Side
        *c Plastigage
        *d No. 1 Journal
        *e Other Journals

        Measure the Plastigage at its widest point.

        Standard Oil Clearance
        Item Specified Condition
        Exhaust side No. 1 journal 0.031 to 0.078 mm (0.00122 to 0.00307 in.)
        Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.)
        Maximum Oil Clearance
        Item Specified Condition
        Exhaust side No. 1 journal 0.10 mm (0.00394 in.)
        Other journals 0.09 mm (0.00354 in.)

        Tech Tips


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

        • If the oil clearance is still more than the maximum after replacing the camshaft, replace the camshaft housing sub-assembly LH.

  19. INSPECT INTAKE MANIFOLD


    1. B00769CC02
      *a Intake Air Surge Tank Assembly Side
      *b Cylinder Head Side

      Using a precision straightedge and feeler gauge, measure the warpage of the surfaces which contact the cylinder head and intake air surge tank assembly.

      Maximum Warpage
      0.10 mm (0.00394 in.)

      Tech Tips

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