ENGINE UNIT INSPECTION


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


    1. A0040CF

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

      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 lash adjuster into a container filled with new engine oil.

    2. A0040N4E12
      Text in Illustration
      *1 Plunger
      *2 Check Ball
      *3 Low Pressure Chamber
      *4 High Pressure Chamber
      *a CORRECT
      *b INCORRECT
      *c Taper Part

      Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

      SST
      09276-75010

    3. Squeeze SST and the valve lash adjuster 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 bleeding is not possible.

    5. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers.

      OK
      Plunger is very difficult to move.

      If the result is not as specified, replace the valve lash adjuster assembly.

  3. INSPECT CHAIN SUB-ASSEMBLY


    1. A0040KIE05
      Text in Illustration
      *a Measurement Length

      Pull the chain sub-assembly with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.

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

      Maximum chain elongation
      115.2 mm (4.54 in.)

      Note

      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.

  4. INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. A0040KIE05
      Text in Illustration
      *a Measurement Length

      Pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.

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

      Maximum chain elongation
      102.1 mm (4.02 in.)

      Note

      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.

  5. INSPECT OIL PUMP DRIVE GEAR


    1. A0043AQE01

      Place the No. 2 chain sub-assembly around the oil pump drive gear.

    2. Using a vernier caliper, measure the diameter of the oil pump drive gear and No. 2 chain sub-assembly.

      Minimum gear diameter (with chain)
      48.2 mm (1.90 in.)

      Note

      The vernier caliper must be in contact with the chain rollers when measuring.

      If the diameter is less than the minimum, replace the No. 2 chain sub-assembly and oil pump drive gear.

  6. INSPECT OIL PUMP DRIVE SHAFT GEAR


    1. A0042K8E01

      Place the No. 2 chain sub-assembly around the oil pump drive shaft gear.

    2. Using a vernier caliper, measure the diameter of the oil pump drive shaft gear and No. 2 chain sub-assembly.

      Minimum gear diameter (with chain)
      48.2 mm (1.90 in.)

      Note

      The vernier caliper must be in contact with the chain rollers when measuring.

      If the diameter is less than the minimum, replace the No. 2 chain sub-assembly and oil pump drive shaft gear.

  7. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. A004081

      Place the chain sub-assembly around the camshaft timing gear assembly.

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

      Minimum gear diameter (with chain)
      96.8 mm (3.81 in.)

      Note

      The vernier caliper must be in contact with the chain rollers when measuring.

      If the diameter is less than the minimum, replace the chain sub-assembly and camshaft timing gear assembly.

  8. INSPECT CAMSHAFT TIMING SPROCKET


    1. A0043XO

      Place the chain sub-assembly around the camshaft timing sprocket.

    2. Using a vernier caliper, measure the diameter of the camshaft timing sprocket and chain sub-assembly.

      Minimum gear diameter (with chain)
      96.8 mm (3.81 in.)

      Note

      The vernier caliper must be in contact with the chain rollers when measuring.

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

  9. INSPECT CRANKSHAFT TIMING SPROCKET


    1. A0043AQE01

      Place the chain sub-assembly around the crankshaft timing sprocket.

    2. Using a vernier caliper, measure the diameter of the crankshaft timing sprocket and chain sub-assembly.

      Minimum gear diameter (with chain)
      51.1 mm (2.01 in.)

      Note

      The vernier caliper must be in contact with the chain rollers when measuring.

      If the diameter is less than the minimum, replace the chain and crankshaft timing gear.

  10. INSPECT CHAIN TENSIONER SLIPPER


    1. A0042WD

      Using a vernier caliper, measure the chain tensioner slipper wear.

      Maximum wear
      1.0 mm (0.0394 in.)

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

  11. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. A0041OE

      Using a vernier caliper, measure the No. 1 chain vibration damper wear.

      Maximum wear
      1.0 mm (0.0394 in.)

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

  12. INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. A00442B

      Using a vernier caliper, measure the No. 2 chain vibration damper wear.

      Maximum wear
      1.0 mm (0.0394 in.)

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

  13. INSPECT CHAIN TENSIONER PLATE


    1. A004244

      Using a vernier caliper, measure the chain tensioner plate wear.

      Maximum wear
      1.0 mm (0.0394 in.)

      If the wear is more than the maximum, replace the chain tensioner plate.

  14. INSPECT NO. 1 CHAIN TENSIONER


    1. A0043QAE03
      Text in Illustration
      *a Lock
      *b Move
      *c Raise

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

    2. Release the cam, then check that the plunger is locked in place by the cam and does not move when pushing with your finger.

      If necessary, replace the No. 1 chain tensioner.

  15. INSPECT CAMSHAFT


    1. A0041X7E01

      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.

        Maximum circle runout
        0.04 mm (0.00157 in.)

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

    2. A00443RE01

      Inspect the cam lobes.


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

        Standard cam lobe height
        41.779 to 41.879 mm (1.6448 to 1.6488 in.)
        Minimum cam lobe height
        41.629 mm (1.6389 in.)

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

    3. A0042B7E01

      Inspect the camshaft journals.


      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter
        Journal Position Specified Condition
        No. 1 34.449 to 34.465 mm (1.3563 to 1.3569 in.)
        Others 22.949 to 22.965 mm (0.90350 to 0.90413 in.)

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

  16. INSPECT NO. 2 CAMSHAFT


    1. A0041X7E01

      Inspect the No. 2 camshaft for runout.


      1. Place the No. 2 camshaft on V-blocks.

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

        Maximum circle runout
        0.04 mm (0.00157 in.)

        If the circle runout is more than the maximum, replace the No. 2 camshaft.

    2. A00443RE01

      Inspect the cam lobes.


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

        Standard cam lobe height
        43.346 to 43.446 mm (1.7065 to 1.7105 in.)
        Minimum cam lobe height
        43.196 mm (1.7006 in.)

        If the cam lobe height is less than the minimum, replace the No. 2 camshaft.

    3. A0042B7E01

      Inspect the camshaft journals.


      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter
        Journal Position Specified Condition
        No. 1 34.449 to 34.465 mm (1.3563 to 1.3569 in.)
        Others 22.949 to 22.965 mm (0.90350 to 0.90413 in.)

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

  17. INSPECT CYLINDER HEAD SET BOLT


    1. A0041MOE04
      Text in Illustration
      *a Measurement Length
      *b Measurement Area
      *c Distance

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

      Standard length
      146.8 to 148.2 mm (5.78 to 5.83 in.)
      Maximum length
      149.2 mm (5.87 in.)

      Tech Tips


      • If the length is greater than the maximum, replace the bolt with a new one. Failure to do so may lead to engine damage.

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

    2. Using a vernier caliper, measure the diameter of the threaded portion of the bolt at its thinnest point.

      Tech Tips

      Use a straightedge to determine the thinnest point of the threaded portion of the bolt.

      Measurement point
      115 mm (4.53 in.)
      Standard diameter
      9.77 to 9.96 mm (0.385 to 0.392 in.)
      Minimum diameter
      9.4 mm (0.370 in.)

      Tech Tips


      • If the diameter is less than the minimum, replace the cylinder head set bolt with a new one. 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.

      Tech Tips

      If a visual check reveals no excessively thin areas, check the center of the bolt (refer to illustration) and find the area that has the smallest diameter.

  18. INSPECT EXHAUST MANIFOLD


    1. A004349

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

      Maximum warpage
      0.7 mm (0.0276 in.)

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