ENGINE UNIT INSPECTION


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


    1. A019LNY

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

      If the roller does not turn smoothly, replace the valve rocker arm sub-assembly.

  2. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    A019NCTE03
    Text in Illustration
    *1 Taper Part
    *2 Plunger
    *3 Low Pressure Chamber
    *4 Check Ball
    *5 High Pressure Chamber
    *a CORRECT
    *b INCORRECT

    Note


    • Keep the adjuster free from dirt and foreign matter.

    • Use only clean engine oil.


    1. Place the lash adjuster into a container full of new engine oil.

    2. 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 lash adjuster 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 high-pressure air from the compression 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 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 CAMSHAFT OIL CLEARANCE

    Note

    Do not turn the camshafts.


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

    2. Place the camshafts on the camshaft housing.

    3. A019OSGE02
      Text in Illustration
      *1 Plastigage

      Lay a strip of Plastigage across each of the camshaft journals.

    4. Install the camshaft bearing caps Click here.

    5. Install the camshaft housing sub-assembly Click here.

    6. Remove the camshaft bearing caps Click here.

    7. A019JTXE02
      Text in Illustration
      *1 Plastigage
      *2 No. 1 Journal
      *3 Other Journal

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      Item Specified Condition
      Intake No. 1 journal 0.035 to 0.072 mm (0.00137 to 0.00283 in.)
      Exhaust No. 1 journal 0.049 to 0.086 mm (0.00193 to 0.00339 in.)
      Other journal 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
      Maximum Oil Clearance
      Item Specified Condition
      Intake No. 1 journal 0.085 mm (0.00335 in.)
      Exhaust No. 1 journal 0.095 mm (0.00374 in.)
      Other journal 0.085 mm (0.00335 in.)

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

  4. INSPECT CAMSHAFT THRUST CLEARANCE


    1. Inspect the intake camshaft.


      1. Install the intake camshaft.

      2. A019N0D

        Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

        If the thrust clearance is more than the maximum, replace the camshaft housing. If the thrust surface is damaged, replace the camshaft.

    2. Inspect the intake and exhaust camshafts.


      1. Install the intake and exhaust camshafts.

      2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

        Standard thrust clearance
        0.060 to 0.155 mm (0.00236 to 0.00610 in.)
        Maximum thrust clearance
        0.170 mm (0.00669 in.)

        If the thrust clearance is more than the maximum, replace the camshaft housing. If the thrust surface is damaged, replace the camshaft.

  5. INSPECT CAMSHAFT


    1. A019MKU

      Inspect the camshaft runout.


      1. Place the camshaft on V-blocks.

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

        Maximum circle runout
        0.03 mm (0.00118 in.)

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

        Tech Tips

        Check the oil clearance after replacing the camshaft.

    2. A019N0V

      Inspect the cam lobes.


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

        Standard Cam Lobe Height
        Item Specified Condition
        Intake 44.163 to 44.305 mm (1.73870 to 1.74429 in.)
        Exhaust 44.144 to 44.286 mm (1.73795 to 1.74354 in.)
        Minimum Cam Lobe Height
        Item Specified Condition
        Intake 44.013 mm (1.73280 in.)
        Exhaust 43.996 mm (1.73213 in.)

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

    3. A019LL2

      Inspect the camshaft journals.


      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter
        Item Specified Condition
        No. 1 journal 34.449 to 34.465 mm (1.35626 to 1.35689 in.)
        Other journals 22.959 to 22.975 mm (0.90390 to 0.90453 in.)

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

  6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. A019KVLE02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

      Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

    2. A019KYDE10
      Text in Illustration
      *1 Camshaft Timing Gear
      *2 Clearance
      *3 Flange
      *a INCORRECT
      *b CORRECT
      *c No Clearance

      Check that there is no clearance between the camshaft timing gear and camshaft flange.

    3. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand.

      Note

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    4. Check the lock of the camshaft timing gear.


      1. Make sure that the camshaft timing gear is locked.

        Note

        Be careful not to damage the camshaft.

    5. A019OYGE05

      Release the lock pin.

      Text in Illustration
      *1 Rubber
      *2 Vinyl Tape
      *3 Knock Pin
      *a Retard Side Path
      *b Advance Side Path
      *c Open
      *d Close

      1. Clean the camshaft journal with non-residue solvent.

      2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        There are 4 oil paths in the grooves of the camshaft. Plug three of the paths with pieces of rubber.

      3. Open a hole at port A shown in the illustration.

      4. A019NIW

        While applying approximately 200 kPa (2.0 kgf/ cm2, 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        CAUTION:

        Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.

        Note

        Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

        Tech Tips


        • The camshaft timing gear assembly may be turned in the advance direction without applying any force.

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

    6. Check for smooth rotation.


      1. Turn the camshaft timing gear within its movable range (26.5 to 28.5°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.

        Note

        Do not allow the camshaft timing gear assembly to lock.

        If it locks, release the lock pin again.

    7. Remove the vinyl tape and rubber pieces from the camshaft.

    8. Remove the bolt and camshaft timing gear.

  7. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A019OQ7E02
      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

      Align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear.

    2. A019KYDE10
      Text in Illustration
      *1 Camshaft Timing Gear
      *2 Clearance
      *3 Flange
      *a INCORRECT
      *b CORRECT
      *c No Clearance

      Check that there is no clearance between the camshaft timing exhaust gear and camshaft flange.

    3. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing exhaust gear by hand.

    4. Check the lock of the camshaft timing exhaust gear.


      1. Make sure that the camshaft timing exhaust gear is locked.

        Note

        Be careful not to damage the camshaft.

    5. A019KULE03
      Text in Illustration
      *1 Vinyl Tape
      *2 Rubber
      *3 Knock Pin
      *a Retard Side Path
      *b Advance Side Path
      *c Open
      *d Close

      Release the lock pin.


      1. Clean the camshaft journal with non-residue solvent.

      2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        There are 4 oil paths in the grooves of the camshaft. Plug 2 paths with rubber pieces.

      3. Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path, as shown in the illustration.

      4. A019L4ZE02
        Text in Illustration
        *1 Retard Side Path
        *2 Advance Side Path

        Apply approximately 200 kPa (2.0 kgf/cm2, 29 psi) of air pressure to the 2 open paths (the advance side path and retard side path).

        Note

        Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.

      5. A019KDZE02
        Text in Illustration
        *1 Retard Side Path
        *2 Advance Side Path
        *3 Hold Pressure
        *4 Decompress

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

        Tech Tips

        The lock pin is released and the camshaft timing exhaust gear turns in the retard direction.

      6. When the camshaft timing exhaust gear moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path.

        Note

        Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear may abruptly shift in the advance direction and break the lock pin or other parts.

    6. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear within its movable range (21.5 to 23.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.

        Note

        When the air pressure is released from the advance side path and then from the retard side path, the gear automatically returns to the most advanced position due to the advance assist spring operation, and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

    7. Check the lock at the most advanced position.


      1. Make sure that the camshaft timing exhaust gear locks at the most advanced position.

    8. Remove the vinyl tape and rubber pieces from the camshaft.

    9. Remove the bolt and camshaft timing gear.

  8. INSPECT CHAIN SUB-ASSEMBLY

    A019NR9E03
    Text in Illustration
    *a Measurement Length

    1. Using a spring scale, pull the chain 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
      137.7 mm (5.42 in.)

      Tech Tips

      Perform the measurement at 3 random places.

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

  9. INSPECT CRANKSHAFT TIMING SPROCKET


    1. A019PLR

      Place the chain around the sprocket.

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

      Minimum sprocket diameter (with chain)
      59.94 mm (2.36 in.)

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

      Tech Tips

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

  10. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A019P6T

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

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

  11. INSPECT CHAIN TENSIONER SLIPPER


    1. A019L8KE03
      Text in Illustration
      *a Depth

      Measure the worn depth of the chain tensioner slipper.

      Maximum depth
      1.0 mm (0.0394 in.)

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

  12. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. A019MYUE03
      Text in Illustration
      *a Depth

      Measure the worn depth of the chain vibration damper.

      Maximum depth
      1.0 mm (0.0394 in.)

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

  13. INSPECT TIMING CHAIN GUIDE


    1. A019NNWE03
      Text in Illustration
      *a Depth

      Measure the worn depth of the timing chain guide.

      Maximum depth
      1.0 mm (0.0394 in.)

      If the depth is more than the maximum, replace the timing chain guide.

  14. INSPECT BALANCE SHAFT THRUST CLEARANCE


    1. A019NZWE02
      Text in Illustration
      *1 No. 1 Balance Shaft

      Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.

      Standard thrust clearance
      0.05 to 0.09 mm (0.00197 to 0.00354 in.)
      Maximum thrust clearance
      0.09 mm (0.00354 in.)

      If the thrust clearance is more than the maximum, replace the engine balancer assembly.

    2. A019MZ4E02
      Text in Illustration
      *1 No. 2 Balance Shaft

      Using a dial indicator, measure the thrust clearance while moving the No. 2 balance shaft back and forth.

      Standard thrust clearance
      0.05 to 0.09 mm (0.00197 to 0.00354 in.)
      Maximum thrust clearance
      0.09 mm (0.00354 in.)

      If the thrust clearance is more than the maximum, replace the engine balancer assembly.

  15. INSPECT BALANCE SHAFT BACKLASH


    1. A019KN1E03
      Text in Illustration
      *a Fix

      Secure the No. 2 balance shaft in place, and then using a dial indicator, measure the backlash of the No. 1 and No. 2 balance shafts as shown in the illustration.

      Standard backlash
      0.04 to 0.16 mm (0.00157 to 0.00630 in.)
      Maximum backlash
      0.16 mm (0.00630 in.)

      Note

      Measure at 3 or more areas around the circumference of the No. 1 and No. 2 balance shafts.

      If the backlash is more than the maximum, replace the engine balancer assembly.

  16. INSPECT CYLINDER HEAD BOLT


    1. A019M3CE15
      Text in Illustration
      *a Measurement Point

      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 (0.427 to 0.433 in.)
      Minimum diameter
      10.6 mm (0.417 in.)
      Measurement point (distance from the seat)
      106 mm (4.17 in.)

      Tech Tips


      • If the diameter is less than the minimum, replace the cylinder head bolt with a new one. Failure to do so may lead to engine damage.

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

  17. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A019LR0

      Using a precision straightedge and feeler gauge, measure the warpage of 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.