ENGINE UNIT INSPECTION

PROCEDURE


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


    1. B0069GF

      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. 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
      B006DTSC01
      *a CORRECT *b INCORRECT
      *c Tapered Path *d Plunger
      *e Low Pressure Chamber *f Check Ball
      *g High Pressure Chamber - -

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

      OK
      Plunger can be pressed 3 times.

      Tech Tips

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

  3. INSPECT CAMSHAFT


    1. Inspect the camshaft runout.


      1. Place the camshaft on V-blocks.

      2. B006D3H

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

        Maximum circle runout
        0.03 mm (0.00118 in.)

        Tech Tips


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

        • Check the oil clearance after replacing the camshaft.

          Click here

    2. B006A1A

      Using a micrometer, measure the cam lobe height.

      Standard Cam Lobe Height
      Item Specified Condition
      Intake camshaft for Bank 1 42.619 to 42.719 mm (1.67791 to 1.68184 in.)
      for Bank 2 42.619 to 42.719 mm (1.67791 to 1.68184 in.)
      Exhaust camshaft for Bank 1 38.539 to 38.639 mm (1.51728 to 1.52121 in.)
      for Bank 2 38.539 to 38.639 mm (1.51728 to 1.52121 in.)
      for Fuel Pump 35.550 to 35.650 mm (1.39960 to 1.40354 in.)
      Minimum Cam Lobe Height
      Item Specified Condition
      Intake camshaft for Bank 1 42.559 mm (1.67554 in.)
      for Bank 2 42.559 mm (1.67554 in.)
      Exhaust camshaft for Bank 1 38.479 mm (1.51491 in.)
      for Bank 2 38.479 mm (1.51491 in.)
      for Fuel Pump 35.490 mm (1.3972 in.)

      Tech Tips

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

    3. Using a micrometer, measure the journal diameter.

      Standard Journal Diameter
      Item Specified
      No. 1 Journal for Intake Side 33.984 to 34.000 mm (1.33795 to 1.33858 in.)
      for Exhaust Side 40.984 to 41.000 mm (1.61354 to 1.61417 in.)
      Other Journals 23.959 to 23.975 mm (0.94326 to 0.94389 in.)

      Tech Tips

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

      Click here

  4. INSPECT CYLINDER HEAD SET BOLT


    1. B006FZFC02
      *a Bolt A
      *b Bolt B
      *c Measurement Point
      *d Measurement Point (Distance from the Seat)

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

      Standard Diameter
      for bolt A
      11.972 to 11.760 mm (0.471 to 0.463 in.)
      for bolt B
      10.974 to 10.794 mm (0.432 to 0.425 in.)
      Minimum Diameter
      for bolt A
      11.60 mm (0.457 in.) less than
      for bolt B
      10.60 mm (0.417 in.) less than
      Measurement Point (Distance from the Seat)
      for bolt A
      115 mm (4.52 in.)
      for bolt B
      105 mm (4.13 in.)

      Tech Tips


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

  5. INSPECT NO. 1 CHAIN SUB-ASSEMBLY


    1. B006FSFC03
      *a Measurement Area

      Using a spring scale, pull the No. 1 chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) and measure the length of the chain using a vernier caliper.

      Maximum chain elongation
      137.38 mm (5.40 in.)

      Tech Tips

      Perform the measurement at 3 random places. If a measurement is more than the maximum, replace the No. 1 chain sub-assembly.

  6. INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. B006FSFC06
      *a Measurement Area

      Using a spring scale, pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) and measure the length of the No. 2 chain using a vernier caliper.

      Maximum chain elongation
      115.72 mm (4.55 in.)

      Tech Tips

      Perform the measurement at 3 random places. If a measurement is more than the maximum, replace the No. 2 chain sub-assembly.

  7. INSPECT OIL PUMP DRIVE CHAIN SUB-ASSEMBLY


    1. B006FSFC01
      *a Measurement Length

      Using a spring scale, pull the oil pump drive 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
      116.35 mm (4.58 in.)

      Note

      Perform the measurement at 3 random places. Use the average of the measurements.

      Tech Tips

      If the average elongation is more than the maximum, replace the oil pump drive chain sub-assembly.

  8. INSPECT OIL PUMP DRIVE SPROCKET


    1. B006ACR

      Place the oil pump drive chain sub-assembly around the oil pump drive sprocket.

    2. Using a vernier caliper, measure the diameter of the oil pump drive sprocket and oil pump drive chain sub-assembly.

      Minimum Gear Diameter (with Oil Pump Drive Chain Sub-assembly)
      62.39 mm (2.45 in.)

      Note

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

      Tech Tips

      If the diameter is less than the minimum, replace the oil pump drive chain sub-assembly and oil pump drive sprocket.

  9. INSPECT OIL PUMP DRIVE SHAFT SPROCKET


    1. B006B3V

      Place the oil pump drive chain sub-assembly around the oil pump drive shaft sprocket.

    2. Using a vernier caliper, measure the diameter of the oil pump drive shaft sprocket and oil pump drive chain sub-assembly.

      Minimum Gear Diameter (with Oil Pump Drive Chain Sub-assembly)
      57.31 mm (2.25 in.)

      Note

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

      Tech Tips

      If the diameter is less than the minimum, replace the oil pump drive chain sub-assembly and oil pump drive shaft sprocket.

  10. INSPECT CAMSHAFT TIMING INTAKE GEAR ASSEMBLY


    1. B006CW0

      for No. 1 Chain Sub-assembly Side:


      1. Place the No. 1 chain sub-assembly around the camshaft timing intake outside gear assembly.

      2. Using a vernier caliper, measure the diameter of the camshaft timing intake gear assembly and No. 1 chain sub-assembly.

        Minimum Gear Diameter (with Chain Sub-assembly)
        113.74 mm (4.47 in.)

        Note

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

        Tech Tips

        If the diameter is less than the minimum, replace the No. 1 chain sub-assembly and camshaft timing intake gear assembly.

    2. B006DVT

      for No. 2 Chain Sub-assembly Side:


      1. Place the No. 2 chain sub-assembly around the camshaft timing intake inside gear assembly.

      2. Using a vernier caliper, measure the diameter of the camshaft timing intake gear assembly and No. 2 chain sub-assembly.

        Minimum Gear Diameter (with Chain Sub-assembly)
        74.55 mm (2.93 in.)

        Note

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

        Tech Tips

        If the diameter is less than the minimum, replace the No. 2 chain sub-assembly and camshaft timing intake gear assembly.

  11. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B006EAY

      Place the No. 2 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 No. 2 chain sub-assembly.

      Minimum Gear Diameter (with Chain Sub-assembly)
      75.01 mm (2.95 in.)

      Note

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

      Tech Tips

      If the diameter is less than the minimum, replace the No. 2 chain sub-assembly and camshaft timing exhaust gear assembly.

  12. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET


    1. Place the No. 1 chain sub-assembly around the crankshaft timing gear or sprocket.

    2. B006ACR

      Using a vernier caliper, measure the diameter of the crankshaft timing gear or sprocket with the No. 1 chain sub-assembly.

      Maximum Sprocket Diameter (with Chain Sub-assembly)
      59.76 mm (2.35 in.)

      Tech Tips


      • The vernier caliper must contact the chain rollers when measuring.

      • If the diameter is more than the maximum, replace the No. 1 chain sub-assembly and crankshaft timing gear or sprocket.

  13. INSPECT IDLE SPROCKET ASSEMBLY


    1. Place the No. 1 chain sub-assembly around the idle sprocket assembly.

    2. B006GBO

      Using a vernier caliper, measure the diameter of the idle sprocket assembly with the No. 1 chain sub-assembly.

      Maximum Sprocket Diameter (with Chain Sub-assembly)
      65.8 mm (2.59 in.)

      Tech Tips


      • The vernier caliper must contact the chain rollers when measuring.

      • If the diameter is more than the maximum, replace the No. 1 chain sub-assembly and idle sprocket assembly.

  14. INSPECT NO. 1 IDLE GEAR SHAFT OIL CLEARANCE


    1. B006EBY

      Using a micrometer, measure the idle gear shaft diameter.

      Standard idle gear shaft diameter
      22.987 to 23.000 mm (0.905 to 0.906 in.)
    2. B006BFG

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

      Standard idle gear inside diameter
      23.020 to 23.030 mm (0.906 to 0.907 in.)

    3. Subtract the idle gear shaft diameter measurement from the idle gear 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.)

      Tech Tips

      If the oil clearance is more than the maximum, replace the No. 1 idle gear shaft and idle sprocket assembly.

  15. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B006C1MC02
      *a Plunger
      *b Stopper Plate

      Turn the stopper plate clockwise to release the lock. Push the plunger and check that it moves smoothly.

      Tech Tips

      If the plunger does not move smoothly, replace the No. 1 chain tensioner assembly.

  16. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B006ASQC03
      *a Depth

      Check that the plunger moves smoothly.

    2. Using a vernier caliper, measure the wear depth of the No. 2 chain tensioner assembly.

      Maximum Depth
      1.0 mm (0.0394 in.)

      Tech Tips

      If the depth is more than the maximum, replace the No. 2 chain tensioner assembly.

  17. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B006EBNC02
      *a Depth

      Check that the plunger moves smoothly.

    2. Using a vernier caliper, measure the wear depth of the No. 3 chain tensioner assembly.

      Maximum Depth
      1.0 mm (0.0394 in.)

      Tech Tips

      If the depth is more than the maximum, replace the No. 3 chain tensioner assembly.

  18. INSPECT CHAIN TENSIONER SLIPPER


    1. B006E05C02
      *a Depth

      Measure the depth of wear of the chain tensioner slipper.

      Maximum depth
      1.0 mm (0.0394 in.)

      Tech Tips

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

  19. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. B006GIQC02
      *a Depth

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

      Maximum depth
      1.0 mm (0.0394 in.)

      Tech Tips

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

  20. INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. B006BY8C01
      *a Depth

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

      Maximum Depth
      1.0 mm (0.0394 in.)

      Tech Tips

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

  21. INSPECT CAMSHAFT THRUST CLEARANCE


    1. Inspect the camshaft thrust clearance (for Bank 1).


      1. Install the intake camshaft sub-assembly RH.

        Click here

      2. Install the exhaust camshaft sub-assembly RH.

        Click here

      3. B006E23

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

        Standard Thrust Clearance
        0.06 to 0.20 mm (0.00236 to 0.00787 in.)
        Maximum Thrust Clearance
        0.25 mm (0.00984 in.)

        Tech Tips


        • If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly.

        • If the thrust surface is damaged, replace the intake camshaft sub-assembly RH or exhaust camshaft sub-assembly RH.

    2. Inspect the camshaft thrust clearance (for Bank 2).


      1. Install the intake camshaft sub-assembly LH.

        Click here

      2. Install the exhaust camshaft sub-assembly LH.

        Click here

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

        Standard Thrust Clearance
        0.06 to 0.20 mm (0.00236 to 0.00787 in.)
        Maximum Thrust Clearance
        0.25 mm (0.00984 in.)

        Tech Tips


        • If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly LH.

        • If the thrust surface is damaged, replace the intake camshaft sub-assembly LH or exhaust camshaft sub-assembly LH.

  22. INSPECT CAMSHAFT OIL CLEARANCE


    1. for Bank 1:


      1. Clean the camshaft bearing caps, camshaft housing sub-assembly and camshaft journals.

      2. Place the camshafts onto the camshaft housing sub-assembly.

      3. B006GEDC02
        *a 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. B006EQDC02
        *a Plastigage
        *b No. 1 Journal
        *c Other Journals

        Measure the Plastigage at its widest point.

        Standard Oil Clearance
        Item Specified Condition
        No. 1 journal 0.035 to 0.072 mm (0.00137 to 0.00283 in.)
        Other journals 0.025 to 0.057 mm (0.000984 to 0.00224 in.)
        Maximum Oil Clearance
        Item Specified Condition
        No. 1 journal 0.085 mm (0.00334 in.)
        Other journals 0.085 mm (0.00334 in.)

        Tech Tips


        • If the oil clearance is more than the maximum, replace the intake camshaft sub-assembly RH or exhaust camshaft sub-assembly RH.

        • If necessary, replace the camshaft housing sub-assembly.

    2. for Bank 2:


      1. Clean the camshaft bearing caps, camshaft housing sub-assembly LH and camshaft journals.

      2. Place the camshafts on the camshaft housing sub-assembly LH.

      3. B006BS1C01
        *a 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. B006DEBC01
        *a Plastigage
        *b No. 1 Journal
        *c Other Journals

        Measure the Plastigage at its widest point.

        Standard Oil Clearance
        Item Specified Condition
        No. 1 Journal 0.035 to 0.072 mm (0.00137 to 0.00283 in.)
        Other Journals 0.025 to 0.057 mm (0.000984 to 0.00224 in.)
        Maximum Oil Clearance
        Item Specified Condition
        No. 1 Journal 0.085 mm (0.00334 in.)
        Other Journals 0.085 mm (0.00334 in.)

        Tech Tips


        • If the oil clearance is more than the maximum, replace the intake camshaft sub-assembly LH or exhaust camshaft sub-assembly LH.

        • If necessary, replace the camshaft housing sub-assembly LH.