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.

      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.

    A01HGKUC19
    *a CORRECT *b INCORRECT
    *c Taper Part *d Low Pressure Chamber
    *e High Pressure Chamber *f Plunger
    *g Check Ball - -

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

    2. 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 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 the 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 can be pressed 3 times.

      If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster with a new one.

  3. INSPECT CHAIN SUB-ASSEMBLY


    1. B005ABZC14
      *a Measurement Area

      Using a spring scale, 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 pins.

      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. A01HGEQC15
      *a Measurement Area

      Using a spring scale, 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 pins.

      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. A01HJYJ

      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 No. 2 chain sub-assembly)
      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. A01HENW

      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 No. 2 chain sub-assembly)
      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. A01HIYH

      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 sub-assembly)
      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 EXHAUST GEAR ASSEMBLY


    1. A01HE9E

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

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

      Minimum gear diameter (with chain sub-assembly)
      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 exhaust gear assembly.

  9. INSPECT CRANKSHAFT TIMING SPROCKET


    1. A01HJYJ

      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 sub-assembly)
      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 sub-assembly and crankshaft timing sprocket.

  10. INSPECT CHAIN TENSIONER SLIPPER


    1. A01HI1J

      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. A01HGFV

      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 CHAIN TENSIONER PLATE


    1. A01HGOQ

      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.

  13. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01HJQ8C04
      *a Raise
      *b Move
      *c Lock

      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 pushed with your finger.

      If necessary, replace the No. 1 chain tensioner.

  14. INSPECT CYLINDER HEAD SET BOLT


    1. A01HF3VC11
      *a Measurement Length
      *b Measuring 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.)

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

    2. Using a vernier caliper, measure the diameter of the elongated thread at the measuring area.

      Distance
      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.)

      If the diameter is less than the minimum, replace the cylinder head set bolt.

      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.

  15. INSPECT EXHAUST MANIFOLD


    1. A01HIIJ

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

      Maximum warpage
      0.7 mm (0.0276 in.)

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