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 from dirt and foreign matter.

    • 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 plunger and use the tip to press down on the check ball inside the plunger.

      SST
      09276-75010
      B00780AC01
      *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 any air.

      OK
      Plunger moves up and down.

      Note

      When bleeding the air from the high-pressure chamber, make sure that the tip of SST is 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.

      Tech Tips

      If the plunger is easy to move, replace the valve lash adjuster assembly.

  3. INSPECT CAMSHAFT


    1. Inspect the camshaft runout.


      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.)

        Tech Tips


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

        • Check the oil clearance after replacing the camshaft.

          Click here

    2. B0073MH

      Inspect the cam lobes. (for intake and exhaust valve)


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

        Standard Cam Lobe Height
        Item Specified Condition
        Intake Side of Bank 1 44.3229 to 44.4229 mm (1.74499 to 1.74893 in.)
        Exhaust Side of Bank 1 44.4377 to 44.5377 mm (1.74951 to 1.75345 in.)
        Intake Side of Bank 2 44.3221 to 44.4221 mm (1.74496 to 1.74890 in.)
        Exhaust Side of Bank 2 44.4356 to 44.5356 mm (1.74943 to 1.75337 in.)
        Minimum Cam Lobe Height
        Item Specified Condition
        Intake Side of Bank 1 44.2229 mm (1.74106 in.)
        Exhaust Side of Bank 1 44.3377 mm (1.74558 in.)
        Intake Side of Bank 2 44.2221 mm (1.74102 in.)
        Exhaust Side of Bank 2 44.3356 mm (1.74549 in.)
    3. B0075R9

      Inspect the cam lobes. (for fuel pump drive)


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

        Standard Cam Lobe Height
        40.554 to 40.654 mm (1.59661 to 1.60055 in.)
        Minimum Cam Lobe Height
        40.454 mm (1.59267 in.)

    4. Using a micrometer, measure the journal diameter. (for Exhaust Side of Bank 1)

      Standard Journal Diameter
      Item Specification
      No. 1 Journal 35.946 to 35.960 mm (1.41519 to 1.41575 in.)
      Other Journals 25.959 to 25.975 mm (1.02201 to 1.02264 in.)

    5. Using a micrometer, measure the journal diameter. (except Exhaust Side of Bank 1)

      Standard Journal Diameter
      Item Specification
      No. 1 Journal 35.946 to 35.960 mm (1.41519 to 1.41575 in.)
      No. 2, 3, 4 Journals 25.959 to 25.975 mm (1.02201 to 1.02264 in.)
      No. 5 Journal 25.969 to 25.985 mm (1.02240 to 1.02303 in.)

      Tech Tips

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

      Click here

  4. INSPECT CYLINDER HEAD SET BOLT

    B0075QTC07
    *a Measurement Length

    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.)

      Tech Tips


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

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

    2. B00736DC16
      *a Measuring Point
      *b 100 mm (3.94 in.)

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

      Standard Diameter
      10.80 to 11.00 mm (0.425 to 0.433 in.)
      Minimum Diameter
      10.70 mm (0.421 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.

  5. INSPECT CHAIN SUB-ASSEMBLY


    1. B0076HEC01
      *a Measurement Length

      Using a spring scale, pull the chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.

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

      Maximum Chain Elongation
      136.7 mm (5.38 in.)

      Tech Tips


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

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

  6. INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. B0076HEC01
      *a Measurement Length

      Using a spring scale, pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.

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

      Maximum Chain Elongation
      137.6 mm (5.42 in.)

      Tech Tips


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

      • If the average elongation is more than the maximum, replace the No. 2 chain sub-assembly.

  7. 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 diameter of the crankshaft timing gear or sprocket with the chain sub-assembly.

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

      Tech Tips


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

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

  8. INSPECT IDLE SPROCKET ASSEMBLY


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

    2. B0073WL

      Using a vernier caliper, measure the diameter of the idle sprocket assembly 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 measurement.

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

  9. INSPECT NO. 1 IDLE GEAR SHAFT OIL CLEARANCE


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

      Standard No. 1 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 sprocket assembly.

      Standard Idle Sprocket Assembly Inside 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 (0.000787 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.

  10. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B0075CCC11
      *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.

  11. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B0076HWC01
      *a Moves Smoothly
      *b Depth

      Check that the plunger moves smoothly.

    2. Using a vernier caliper, measure the wear depth 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.

  12. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B00734AC01
      *a Moves Smoothly
      *b Depth

      Check that the plunger moves smoothly.

    2. Using a vernier caliper, measure the wear depth 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.

  13. INSPECT CHAIN TENSIONER SLIPPER


    1. B00748YC01
      *a Depth

      Measure the wear depth 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.

  14. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. B007403C01
      *a Depth

      Using a vernier caliper, measure the wear depth 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.

  15. INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. B0075DGC01
      *a Depth

      Using a vernier caliper, measure the wear depth 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.

  16. 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 onto the camshaft housing sub-assembly RH.

      3. B0077EHC02
        *a 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. B0075NJC02
        *a Plastigage
        *b No. 1 Journal
        *c No. 2 Journal
        *d No. 3 Journal
        *e No. 4 Journal
        *f No. 5 Journal

        Measure the Plastigage at its widest point.

        Standard Oil Clearance
        Item Specified Condition
        No. 1 Journal 0.040 to 0.063 mm (0.00157 to 0.00248 in.)
        No. 2, 3, 4 Journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
        No. 5 Journal 0.015 to 0.052 mm (0.000591 to 0.00205 in.)
        Maximum Oil Clearance
        Item Specified Condition
        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 or No. 2 camshaft.

        • If necessary, 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. B007320C02
        *a 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. B0075JTC02
        *a Plastigage
        *b No. 1 Journal
        *c Other Journals

        Measure the Plastigage at its widest point.

        Standard Oil Clearance
        Item Specified Condition
        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 Specified Condition
        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 No. 3 camshaft sub-assembly or No. 4 camshaft sub-assembly.

        • If necessary, replace the camshaft housing sub-assembly LH.

  17. INSPECT EXHAUST MANIFOLD


    1. B0075TAC01
      *a for Bank 1
      *b for Bank 2

      Using a precision straightedge and feeler gauge, check the surface which contacts the cylinder head sub-assembly and cylinder head LH for warpage.

      Maximum Warpage
      0.5 mm (0.0197 in.)

      Tech Tips

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

  18. INSPECT INTAKE MANIFOLD


    1. B0077N4C02
      *a Intake Air Surge Tank Side
      *b Cylinder Head Side

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

      Maximum Warpage
      0.10 mm (0.00394 in.)

      Tech Tips

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