ENGINE UNIT INSPECTION

PROCEDURE

  1. INSPECT CAMSHAFT TIMING SPROCKET ASSEMBLY

    1. Temporarily install the camshaft timing sprocket assembly to the camshaft with the bolt.

    2. Check the lock of the camshaft timing sprocket assembly.

      1. Make sure that the camshaft timing sprocket assembly is locked.

    3. Release the lock pin.

      1. A297766C01

        *a

        Retard Side Path

        *b

        Advance Side Path

        *c

        Open

        *d

        Closed
        V100144

        Rubber Piece
        V100145

        Vinyl Tape

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

        Tip:

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

      2. 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.

      3. A298026C01

        *a

        Advance Side Path

        *b

        Retard 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 air pressure to keep oil from spraying.

      4. A298027C02

        *a

        Advance Side Path

        *b

        Retard Side Path
        V100135

        Turn

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

        Tip:

        The lock pin is released and the camshaft timing sprocket assembly turns in the retard direction.

      5. When the camshaft timing sprocket assembly moves to the most advanced position, release the air pressure from the retard side path, and then from the advance side path.

        Note:

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

    4. Check for smooth rotation.

      1. Turn the camshaft timing sprocket assembly within its movable range (25°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the sprocket turns smoothly.

        Note:

        Perform this check by hand, instead of using air pressure.

    5. Check the lock in the most retarded position.

      1. Confirm that the camshaft timing sprocket assembly locks at the most retarded position.

  2. INSPECT CHAIN SUB-ASSEMBLY

    A104129

    1. Visually check the chain sub-assembly for wear or cracks.

      Note:

      If the chain sub-assembly is worn or cracked, replace the chain sub-assembly and check the sprocket.

    2. A162995C47

      *a

      Measurement Length

      Using a spring scale, pull the chain sub-assembly with a force of 225 N (23 kgf, 50.6 lbf) as shown in the illustration.

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

      Maximum Chain Elongation

      114.1 mm (4.49 in.)

      Tip:

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

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

  3. INSPECT CAMSHAFT TIMING SPROCKET ASSEMBLY

    1. A324338C01

      *a

      Chain Roller

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

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

      Minimum Gear Diameter (with Chain)

      96.8 mm (3.811 in.)

      Note:

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

      Tip:

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

  4. INSPECT CAMSHAFT TIMING GEAR

    1. A324339C01

      *a

      Chain Roller

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

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

      Minimum Gear Diameter (with Chain)

      96.8 mm (3.811 in.)

      Note:

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

      Tip:

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

  5. INSPECT CRANKSHAFT TIMING SPROCKET

    1. A324340C01

      *a

      Chain Roller

      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 (2.012 in.)

      Note:

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

      Tip:

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

  6. INSPECT TIMING CHAIN TENSION ARM

    1. A324330

      Using a vernier caliper, measure the timing chain tension arm wear.

      Maximum Wear

      0.5 mm (0.0197 in.)

      Tip:

      If the wear is greater than the maximum, replace the timing chain tension arm.

  7. INSPECT TIMING CHAIN GUIDE

    1. A324331

      Using a vernier caliper, measure the timing chain guide wear.

      Maximum Wear

      0.5 mm (0.0197 in.)

      Tip:

      If the wear is greater than the maximum, replace the timing chain guide.

  8. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

    1. A298022C02

      *a

      Stopper Plate

      *b

      Plunger

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

      Tip:

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

  9. INSPECT CAMSHAFT

    1. Inspect the camshaft for runout.

      1. A324332

        Using V-blocks and a dial indicator, measure the runout of the 3rd journal.

        Maximum Runout

        0.03 mm (0.00118 in.)

        Tip:

        The runout is half of the value on the indicator when the camshaft is turned 1 revolution.

        If the runout is greater than the maximum, replace the camshaft.

    2. Inspect the cam lobes.

      1. A324333

        Using a micrometer, measure the cam lobe height.

        Standard Cam Lobe Height

        41.409 to 41.509 mm (1.6303 to 1.6342 in.)

        Minimum Cam Lobe Height

        41.399 mm (1.6299 in.)

        Tip:

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

    3. Inspect the camshaft journals.

      1. A324334

        Using a micrometer, measure the journal diameter.

        Standard Journal Diameter

        Journal Position

        Specification

        No. 1

        33.974 to 33.990 mm (1.3376 to 1.3382 in.)

        Other

        22.949 to 22.965 mm (0.9035 to 0.9041 in.)
        Tip:

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

        Click here

  10. INSPECT NO. 2 CAMSHAFT

    1. Inspect the No. 2 camshaft for runout.

      1. A324335

        Using V-blocks and a dial indicator, measure the runout of the 3rd journal.

        Maximum Runout

        0.03 mm (0.00118 in.)

        Tip:

        The runout is half of the value on the indicator when the No. 2 camshaft is turned 1 revolution.

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

    2. Inspect the cam lobes.

      1. A324336

        Using a micrometer, measure the cam lobe height.

        Standard Cam Lobe Height

        40.972 to 41.072 mm (1.6131 to 1.6170 in.)

        Minimum Cam Lobe Height

        40.872 mm (1.6091 in.)

        Tip:

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

    3. Inspect the No. 2 camshaft journals.

      1. A324337

        Using a micrometer, measure the journal diameter.

        Standard Journal Diameter

        Journal Position

        Specification

        No. 1

        25.979 to 25.995 mm (1.0228 to 1.0234 in.)

        Other

        22.949 to 22.965 mm (0.9035 to 0.9041 in.)
        Tip:

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

        Click here

  11. INSPECT CYLINDER HEAD SET BOLT

    A104216C01

    *a

    Measurement Length

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

      Standard Bolt Length

      121.0 to 122.0 mm (4.7638 to 4.8031 in.)

      Maximum Bolt Length

      123.5 mm (4.8622 in.)

      Tip:

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