ENGINE UNIT INSPECTION


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


    1. A01NFVR

      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. A01NHRRE11

      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 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. A01NF56

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

        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. A01NGRC

      Using a micrometer, measure the cam lobe height.

      Standard Cam Lobe Height
      Item Specification
      Intake camshaft 44.316 to 44.416 mm (1.7448 to 1.7486 in.)
      Exhaust camshaft 43.390 to 43.490 mm (1.7083 to 1.7122 in.)
      Minimum Cam Lobe Height
      Item Specification
      Intake camshaft 44.166 mm (1.7388 in.)
      Exhaust camshaft 43.240 mm (1.7024 in.)

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

    3. A01NFE3

      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 (1.0221 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. A01NGCVE04
      Text in Illustration
      *1 Key Groove
      *2 Straight Pin

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

    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the groove.

      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 the camshaft.

    5. A01NFGH

      Tighten the flange bolt while holding the camshaft.

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

    6. 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.

    7. A01NE1YE07

      Release the lock pin.


      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. A01NGBIE08
        Text in Illustration
        *1 Advanced Side Path
        *2 Retard Side Path

        Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the 2 opened paths.

        CAUTION:

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

      4. A01NHL9E06

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

        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.

    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. A01ND8ZE03

      Remove the flange bolt and camshaft timing gear assembly.

      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 CYLINDER HEAD SET BOLT


    1. A01NDNGE04

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

      Standard diameter
      10.85 to 11.00 mm (0.4272 to 0.4330 in.)
      Minimum diameter
      10.70 mm (0.4212 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.

  6. INSPECT CHAIN SUB-ASSEMBLY


    1. A01NG9ZE06

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

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

      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.

  7. INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. A01NG9ZE06

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

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

      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.

  8. INSPECT CRANKSHAFT TIMING SPROCKET


    1. Place the chain around the sprocket.

    2. A01NDS2

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

      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 No. 1 chain and sprocket.

  9. INSPECT IDLE SPROCKET ASSEMBLY


    1. Place the chain around the sprocket.

    2. A01NH33

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

      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 No. 1 chain and sprocket.

  10. INSPECT IDLE GEAR SHAFT OIL CLEARANCE


    1. A01NEW1

      Using a micrometer, measure the idle gear shaft diameter.

      Standard idle gear shaft diameter
      22.987 to 23.000 mm (0.9050 to 0.9055 in.)
    2. A01NFJO

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

      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.

  11. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01NH65E07
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

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

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

  12. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01NFKJE02
      Text in Illustration
      *1 Depth

      Check that the plunger moves smoothly.

    2. 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.

  13. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01NDC6E02
      Text in Illustration
      *1 Depth

      Check that the plunger moves smoothly.

    2. 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.

  14. INSPECT CHAIN TENSIONER SLIPPER


    1. A01NGGQE02
      Text in Illustration
      *1 Depth

      Measure the worn depth of the chain tensioner slipper.

      Maximum depth
      1.0 mm (0.0394 in.)

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

  15. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. A01NGX8E02
      Text in Illustration
      *1 Depth

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

      Maximum depth
      1.0 mm (0.0394 in.)

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

  16. INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. A01NDXNE02
      Text in Illustration
      *1 Depth

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

      Maximum depth
      1.0 mm (0.0394 in.)

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

  17. INSPECT CAMSHAFT THRUST CLEARANCE


    1. Inspect the bank 1 camshaft thrust clearance.


      1. Install the bank 1 camshaft Click here.

      2. A01NH4C

        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 camshaft housing. 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 camshaft housing. If the thrust surface is damaged, replace the camshaft.

  18. INSPECT CAMSHAFT OIL CLEARANCE


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

    2. Place the camshafts on the camshaft housing.

    3. A01NGWCE02
      Text in Illustration
      *1 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. A01NFI8E06
      Text in Illustration
      *1 Plastigage
      *2 No. 1 Journal
      *3 Other Journals

      Measure the Plastigage at its widest point.

      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.

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

    8. Place the camshafts on the camshaft housing.

    9. A01NGHCE02
      Text in Illustration
      *1 Plastigage

      Lay a strip of Plastigage across each camshaft journal.

    10. Install the camshaft bearing caps Click here.

      Note

      Do not turn the camshaft.

    11. Remove the camshaft bearing caps Click here.

    12. A01NGKRE04
      Text in Illustration
      *1 Plastigage
      *2 No. 1 Journal
      *3 Other Journals

      Measure the Plastigage at its widest point.

      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.

  19. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01NFDD

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

      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.

  20. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01ND9Y

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

      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.

  21. INSPECT INTAKE MANIFOLD


    1. A01NDNYE06

      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.