ENGINE UNIT INSPECTION

PROCEDURE

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

    1. A125485

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

      Tip:

      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 matter.

    • Only use clean engine oil.

    1. Place the valve lash adjuster assembly into a container filled with engine oil.

    2. A286731C06

      *a

      Correct

      *b

      Incorrect

      *c

      Taper Part

      *d

      Low Pressure Chamber

      *e

      High Pressure Chamber

      *f

      Plunger

      *g

      Check Ball

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

      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 it.

      OK

      Plunger moves up and down.

      Note:

      When bleeding 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, the high-pressure chamber will not be bled.

    5. After bleeding, remove SST. Then try to quickly and firmly press the plunger with a finger.

      OK

      Plunger is very difficult to move.

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

  3. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    1. Install the camshaft timing gear assembly.

      Click here

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

      1. Confirm that the camshaft timing gear assembly is locked.

    3. A162971C01

      *a

      Open

      *b

      Close

      *c

      Advance Side Path

      *d

      Vinyl Tape

      *e

      Rubber

      Release the lock pin.

      1. 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 groove of the camshaft. Plug 3 of the paths with rubber pieces.

      2. Prick a hole in the tape placed on the advance side path.

      3. A153834

        While applying approximately 150 kPa (1.5 kgf/cm2, 22 psi) of air pressure to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        CAUTION:

        Cover the path with a piece of cloth when applying pressure to keep oil from spraying.

        Note:

        Do not lock the camshaft timing gear assembly. If it is locked, release the lock pin again.

        Tip:

        • Depending on the air pressure applied, 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.

    4. Check for smooth rotation.

      1. Turn the camshaft timing gear assembly 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 lock the camshaft timing gear assembly. If it is locked, release the lock pin again.

  4. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    1. Install the camshaft timing exhaust gear assembly.

      Click here

    2. Check the lock of the camshaft timing exhaust gear assembly.

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

    3. A152653C01

      *a

      Open

      *b

      Close

      *c

      Advance Side Path

      *d

      Retard Side Path

      *e

      Vinyl Tape

      *f

      Rubber

      Release the lock pin.

      1. 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 groove of the camshaft. Plug 2 of the paths with rubber pieces.

      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. A152656C01

        *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 the retard side path).

        CAUTION:

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

      4. A152659C01

        *a

        Decompress

        *b

        Hold Pressure

        *c

        Advance Side Path

        *d

        Retard Side Path

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

        Tip:

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

      5. When the camshaft timing exhaust gear assembly 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 assembly may abruptly shift in the advance direction and break the lock pin or other parts.

    4. Check for smooth rotation.

      1. Turn the camshaft timing exhaust gear assembly within its movable range (19 to 21°) 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.

    5. Check the lock at the most advanced position.

      1. Make sure that the camshaft timing exhaust gear assembly is locked at the most advanced position.

  5. INSPECT CHAIN SUB-ASSEMBLY

    1. A162995C30

      *a

      Measurement Length

      Pull the chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.

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

      Maximum chain elongation

      115.2 mm (4.535 in.)

      Note:

      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.

  6. INSPECT NO. 2 CHAIN SUB-ASSEMBLY

    1. A162995C31

      *a

      Measurement Length

      Pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.

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

      Maximum chain elongation

      102.1 mm (4.019 in.)

      Note:

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

      If the average elongation is greater than the maximum, replace the No. 2 chain sub-assembly.

  7. INSPECT OIL PUMP DRIVE GEAR

    1. A053035

      Place the chain around the oil pump drive gear.

    2. Using a vernier caliper, measure the diameter of the oil pump drive gear and chain.

      Minimum gear diameter (with chain)

      48.2 mm (1.898 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 oil pump drive gear.

  8. INSPECT OIL PUMP DRIVE SHAFT GEAR

    1. A053036

      Place the chain around the oil pump drive shaft gear.

    2. Using a vernier caliper, measure the diameter of the oil pump drive shaft gear and chain.

      Minimum gear diameter (with chain)

      48.2 mm (1.898 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 oil pump drive shaft gear.

  9. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    1. A063864

      Place the chain around the camshaft timing gear assembly.

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

      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.

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

  10. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    1. A150911

      Place the chain around the camshaft timing exhaust gear assembly.

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

      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.

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

  11. INSPECT CRANKSHAFT TIMING SPROCKET

    1. A053035

      Place the chain around the crankshaft timing sprocket.

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

      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.

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

  12. INSPECT CHAIN TENSIONER SLIPPER

    1. A150912

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

      Maximum wear

      1.0 mm (0.0394 in.)

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

  13. INSPECT NO. 1 CHAIN VIBRATION DAMPER

    1. A150913

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

      Maximum wear

      1.0 mm (0.0394 in.)

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

  14. INSPECT NO. 2 CHAIN VIBRATION DAMPER

    1. A150914

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

      Maximum wear

      1.0 mm (0.0394 in.)

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

  15. INSPECT CHAIN TENSIONER PLATE

    1. A126893

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

      Maximum wear

      1.0 mm (0.0394 in.)

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

  16. INSPECT NO. 1 CHAIN TENSIONER

    1. A234707C01

      *a

      Raise

      *b

      Move

      *c

      Lock

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

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

  17. INSPECT CAMSHAFT

    1. EM01628

      Inspect the camshaft for runout.

      1. Place the camshaft on V-blocks.

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

        Maximum runout

        0.04 mm (0.00157 in.)

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

    2. A036687

      Inspect the cam lobes.

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

        Standard cam lobe height

        42.816 to 42.916 mm (1.6857 to 1.6896 in.)

        Minimum cam lobe height

        42.666 mm (1.6798 in.)

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

    3. A036688

      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 (1.35626 to 1.35689 in.)

        Other

        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

  18. INSPECT NO. 2 CAMSHAFT

    1. EM01628

      Inspect the No. 2 camshaft for runout.

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

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

        Maximum runout

        0.04 mm (0.00157 in.)

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

    2. A036687

      Inspect the cam lobes.

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

        Standard cam lobe height

        44.336 to 44.436 mm (1.7455 to 1.7494 in.)

        Minimum cam lobe height

        44.186 mm (1.7396 in.)

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

    3. A036688

      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 (1.35626 to 1.35689 in.)

        Other

        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

  19. INSPECT CYLINDER HEAD SET BOLT

    1. A162972C03

      *a

      Measurement Length

      *b

      Measurement Point

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

      Standard length

      146.8 to 148.2 mm (5.7795 to 5.8346 in.)

      Maximum length

      149.2 mm (5.874 in.)

      Tip:

      • If the length is greater than the maximum, 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.

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

      Tip:

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

      Standard diameter

      9.77 to 9.96 mm (0.3846 to 0.3921 in.)

      Minimum diameter

      9.4 mm (0.3701 in.)

      Tip:

      • 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.

  20. INSPECT EXHAUST MANIFOLD

    1. A158847

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

      Maximum warpage

      0.7 mm (0.0276 in.)

      If the warpage is greater than the maximum, replace the manifold.