ENGINE UNIT INSPECTION

PROCEDURE

1. INSPECT CHAIN SUB-ASSEMBLY

   
   
   1. 

      Text in Illustration

      *a	Measuring Area

      Using a spring scale, pull the chain sub-assembly with a force of 140 N (14.3 kgf, 31.5 lbf) and measure the length of it.

      Maximum length
      124.2 mm (4.89 in.)

      If the length is greater than the maximum, replace the chain sub-assembly.

      Tech Tips

      Perform the measurement at 3 or more random places to obtain the average length.

2. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

   
   
   1. 

      Text in Illustration

      *1	Ratchet Pawl

      Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.

   2. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.

3. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

   
   

   1. Wrap the chain sub-assembly around the camshaft timing gear assembly.

   2. 

      Using a vernier caliper, measure the diameter of the camshaft timing gear assembly with the chain sub-assembly.

      Standard diameter
      97.4 mm (3.83 in.)

      Minimum diameter
      96.2 mm (3.79 in.)

      Note

      The vernier caliper must come into contact with the chain rollers when measuring.

      If the diameter is less than the minimum, replace the camshaft timing gear assembly.

4. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET

   
   

   1. Wrap the chain sub-assembly around the camshaft timing gear or sprocket.

   2. 

      Using a vernier caliper, measure the diameter of the camshaft timing gear or sprocket with the chain sub-assembly.

      Standard diameter
      97.4 mm (3.83 in.)

      Minimum diameter
      96.2 mm (3.79 in.)

      Note

      The vernier caliper must come into contact with the chain rollers when measuring.

      If the diameter is less than the minimum, replace the camshaft timing gear or sprocket.

5. INSPECT CHAIN TENSIONER SLIPPER

   
   

   1. 

      Measure the chain tensioner slipper wear.

      Maximum wear
      1.0 mm (0.0394 in.)

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

6. INSPECT NO. 1 CHAIN VIBRATION DAMPER

   
   

   1. 

      Measure the vibration damper wear.

      Maximum wear
      1.0 mm (0.0394 in.)

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

7. INSPECT CYLINDER HEAD SET BOLT

   
   
   1. 

      Text in Illustration

      *a

      Length

      Using a vernier caliper, measure the length of the cylinder head set bolts from the seat to the end.

      Standard length
      142.8 to 144.2 mm (5.62 to 5.68 in.)

      Maximum length
      147.1 mm (5.79 in.)

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

8. INSPECT EXHAUST MANIFOLD

   
   

   1. 

      Using a precision straightedge and feeler gauge, measure the surface contacting the exhaust manifold for warpage.

      Maximum warpage
      0.7 mm (0.0276 in.)

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