ENGINE UNIT INSPECTION

PROCEDURE


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


    1. B006ZUN

      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 from dirt and foreign matter.

    • Only use clean engine oil.


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

    2. B008787C08
      *a Tapered Path
      *b Plunger
      *c Check Ball
      *d Correct
      *e Incorrect
      *f Low Pressure Chamber
      *g High Pressure Chamber

      Insert the tip of SST into the 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 any air.

      OK
      Plunger moves up and down.

      Note

      When bleeding the air from the high-pressure chamber, make sure that the tip of SST is 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 by hand.

      OK
      Plunger is very difficult to move.

      Tech Tips

      If the plunger is easy to move, replace the valve lash adjuster assembly.

  3. INSPECT CAMSHAFT


    1. Inspect the camshaft for runout.


      1. Place the camshaft on V-blocks.

      2. B006WV0

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

        Maximum Runout
        0.04 mm (0.00157 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. B006XYU

      Using a micrometer, measure the cam lobe height.

      Standard Cam Lobe Height
      Item Specified Condition
      Intake camshaft 44.335 to 44.435 mm (1.74547 to 1.74941 in.)
      Exhaust camshaft 43.866 to 43.966 mm (1.72701 to 1.73094 in.)
      Exhaust (for Fuel Pump) 40.554 to 40.654 mm (1.59661 to 1.60055 in.)
      Minimum Cam Lobe Height
      Item Specified Condition
      Intake camshaft 44.235 mm (1.74154 in.)
      Exhaust camshaft 43.766 mm (1.72307 in.)
      Exhaust (for Fuel Pump) 40.454 mm (1.59268 in.)

      Tech Tips

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

    3. B006XAX

      Using a micrometer, measure the journal diameter.

      Standard Journal Diameter
      Item Specified Condition
      No. 1 journal 35.946 to 35.960 mm (1.41519 to 1.41575 in.)
      No. 2, No. 3, No. 4 journals 25.959 to 25.975 mm (1.02201 to 1.02264 in.)
      No. 5 journal 25.969 to 25.985 mm (1.02240 to 1.02303 in.)

      Tech Tips

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

      Click here

  4. INSPECT CYLINDER HEAD SET BOLT


    1. B0088NHC01
      *a Measurement Point
      *b 100 mm

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

      Standard Diameter
      10.85 to 11.00 mm (0.427 to 0.433 in.)
      Minimum Diameter
      10.70 mm (0.421 in.)
      Measurement Point (Distance from the Seat)
      100 mm (3.94 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 CHAIN SUB-ASSEMBLY


    1. B0088CVC14
      *a Measurement Length

      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 links.

      Maximum Chain Elongation
      137.8 mm (5.43 in.)

      Tech Tips


      • 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.

  6. INSPECT NO. 2 CHAIN SUB-ASSEMBLY


    1. B0088CVC15
      *a Measurement Length

      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 links.

      Maximum Chain Elongation
      137.8 mm (5.43 in.)

      Tech Tips


      • 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.

  7. INSPECT CRANKSHAFT TIMING SPROCKET


    1. Place the chain sub-assembly around the crankshaft timing sprocket.

    2. B006Z5Y

      Using a vernier caliper, measure the diameter of the crankshaft timing sprocket with the chain sub-assembly.

      Maximum Sprocket Diameter (with Chain Sub-assembly)
      62.2 mm (2.45 in.)

      Tech Tips


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

      • If the diameter is more than the maximum, replace the chain sub-assembly and crankshaft timing sprocket.

  8. INSPECT IDLE SPROCKET ASSEMBLY


    1. Place the chain sub-assembly around the idle sprocket assembly.

    2. B006Z4L

      Using a vernier caliper, measure the diameter of the idle sprocket assembly with the chain sub-assembly.

      Maximum Sprocket Diameter (with Chain Sub-assembly)
      65.2 mm (2.57 in.)

      Tech Tips


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

      • If the diameter is more than the maximum, replace the chain sub-assembly and idle sprocket assembly.

  9. INSPECT NO. 1 IDLE GEAR SHAFT OIL CLEARANCE


    1. B006ZJT

      Using a micrometer, measure the diameter of the No. 1 idle gear shaft.

      Standard No. 1 Idle Gear Shaft Diameter
      22.987 to 23.000 mm (0.905 to 0.906 in.)
    2. B0070O6

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

      Standard Idle Sprocket Assembly Inside Diameter
      23.020 to 23.030 mm (0.906 to 0.907 in.)

    3. Subtract the No. 1 idle gear shaft diameter measurement from the idle sprocket assembly 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.

  10. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B0086MGC01
      *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.

  11. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B0086VYC01
      *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.

  12. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B0084VWC01
      *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.

  13. INSPECT CHAIN TENSIONER SLIPPER


    1. B00873OC01
      *a Depth

      Measure the wear depth 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.

  14. INSPECT NO. 1 CHAIN VIBRATION DAMPER


    1. B0088YHC01
      *a Depth

      Using a vernier caliper, measure the wear depth 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.

  15. INSPECT NO. 2 CHAIN VIBRATION DAMPER


    1. B0086IBC01
      *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.

  16. INSPECT CAMSHAFT THRUST CLEARANCE


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


      1. Install the camshaft.

        Click here

      2. Install the No. 2 camshaft.

        Click here

      3. B00717F

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

        Standard Thrust Clearance
        0.08 to 0.13 mm (0.00315 to 0.00512 in.)
        Maximum Thrust Clearance
        0.18 mm (0.00709 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 camshaft or No. 2 camshaft.

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


      1. Install the No. 3 camshaft sub-assembly.

        Click here

      2. Install the No. 4 camshaft sub-assembly.

        Click here

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

        Standard Thrust Clearance
        0.08 to 0.13 mm (0.00315 to 0.00512 in.)
        Maximum Thrust Clearance
        0.18 mm (0.00709 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 No. 3 camshaft sub-assembly or No. 4 camshaft sub-assembly.

  17. 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. B0083GRC01
        *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. B0088ZYC02
        *a Plastigage
        *b No. 1 Journal
        *c No. 2 journal
        *d No. 3 journal
        *e No. 4 journal
        *f No. 5 journal

        Measure the Plastigage at its widest point.

        Standard Oil Clearance
        Item Specified Condition
        No. 1 journal 0.032 to 0.063 mm (0.00126 to 0.00248 in.)
        No. 2, No. 3, No. 4 journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
        No. 5 journal 0.015 to 0.052 mm (0.000591 to 0.00205 in.)
        Maximum Oil Clearance
        Item Specified Condition
        No. 1 journal 0.10 mm (0.00394 in.)
        No. 2, No. 3, No. 4 journals 0.10 mm (0.00394 in.)
        No. 5 journal 0.10 mm (0.00394 in.)

        Tech Tips


        • If the oil clearance is more than the maximum, replace the camshaft or No. 2 camshaft.

        • 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. B0085KGC01
        *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. B0086REC01
        *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 0.032 to 0.063 mm (0.00126 to 0.00248 in.)
        Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.)
        Maximum Oil Clearance
        Item Specified Condition
        No. 1 journal 0.10 mm (0.00394 in.)
        Other journals 0.10 mm (0.00394 in.)

        Tech Tips


        • If the oil clearance is more than the maximum, replace the No. 3 camshaft sub-assembly or No. 4 camshaft sub-assembly.

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

  18. INSPECT INTAKE MANIFOLD

    B008472C01
    *a Cylinder Head Side
    *b Surge Tank Side

    1. Cylinder head side:


      1. Using a precision straightedge and feeler gauge, check the surface which contacts the cylinder head sub-assembly and cylinder head LH for warpage.

        Maximum Warpage
        0.1 mm (0.00394 in.)

        Tech Tips

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

    2. Surge tank side:


      1. Using a precision straightedge and feeler gauge, check the surface which contacts the intake air surge tank assembly for warpage.

        Maximum Warpage
        0.1 mm (0.00394 in.)

        Tech Tips

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

  19. INSPECT EXHAUST MANIFOLD


    1. B0071IJ

      Using a precision straightedge and feeler gauge, check the surface which contacts the cylinder head sub-assembly and cylinder head LH for warpage.

      Maximum Warpage
      0.7 mm (0.0276 in.)

      Tech Tips

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