INSPECTION

PROCEDURE

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

(a) Turn the roller by hand to check that it turns smoothly. HINT: If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.

2. INSPECT INTAKE CAMSHAFT SUB-ASSEMBLY

(a) Inspect the intake camshaft sub-assembly for runout. (1) Place the intake camshaft sub-assembly on V-blocks. (2) Using a dial indicator, measure the runout at the center journal. Maximum Runout: 0.03 mm (0.00118 in.) HINT: If the runout is more than the maximum, replace the intake camshaft sub-assembly. Check the intake camshaft sub-assembly oil clearance after replacing the intake camshaft sub-assembly.

(b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard Cam Lobe Height: 42.615 to 42.715 mm (1.67775 to 1.68169 in.) Minimum Cam Lobe Height: 42.505 mm (1.67342 in.) HINT: If the cam lobe height is less than the minimum, replace the intake camshaft sub-assembly.

(c) Inspect the intake camshaft sub-assembly journals. (1) Using a micrometer, measure the journal diameter. Standard Journal Diameter: Item Specified Condition No. 1 journal 33.984 to 34.000 mm (1.33795 to 1.33858 in.) Other journals 23.959 to 23.975 mm (0.94327 to 0.94390 in.) HINT: If the journal diameter is not as specified, check the intake camshaft sub-assembly oil clearance. Click here

3. INSPECT EXHAUST CAMSHAFT SUB-ASSEMBLY

(a) Inspect the exhaust camshaft sub-assembly for runout. (1) Place the exhaust camshaft sub-assembly on V-blocks. (2) Using a dial indicator, measure the runout at the center journal. Maximum Runout: 0.03 mm (0.00118 in.) HINT: If the runout is more than the maximum, replace the exhaust camshaft sub-assembly. Check the camshaft oil clearance after replacing the exhaust camshaft sub-assembly.

(b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard Cam Lobe Height: Item Specified Condition Exhaust camshaft sub-assembly 42.140 to 42.240 mm (1.65905 to 1.66299 in.) Exhaust camshaft sub-assembly (for Fuel Pump) 42.946 to 43.046 mm (1.69078 to 1.69472 in.) Minimum Cam Lobe Height: Item Specified Condition Exhaust camshaft sub-assembly 42.030 mm (1.65472 in.) Exhaust camshaft sub-assembly (for Fuel Pump) 42.836 mm (1.68645 in.) HINT: If the cam lobe height is less than the minimum, replace the exhaust camshaft sub-assembly.

(c) Inspect the exhaust camshaft sub-assembly journals. (1) Using a micrometer, measure the journal diameter. Standard Journal Diameter: Item Specified Condition No. 1 journal 40.984 to 41.000 mm (1.61354 to 1.61417 in.) Other journals 23.959 to 23.975 mm (0.94327 to 0.94390 in.) HINT: If the journal diameter is not as specified, check the camshaft oil clearance. Click here

4. INSPECT CAMSHAFT OIL CLEARANCE

(a) Clean the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 2 No. 3 camshaft bearing caps, camshaft housing sub-assembly and camshaft journals.

(b) Place the intake camshaft sub-assembly and exhaust camshaft sub-assembly on the camshaft housing sub-assembly.

(c) Lay a strip of Plastigage across each of the camshaft journals.

*a Plastigage

(d) Install the camshaft bearing caps.

Click here

NOTICE:

Do not turn the camshafts.

(e) Remove the camshaft bearing caps.

Click here

(f) Measure the Plastigage at its widest point. Standard Oil Clearance (for intake camshaft sub-assembly): Item Specified Condition No. 1 journal 0.035 to 0.072 mm (0.00138 to 0.00283 in.) Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.) Standard Oil Clearance (for exhaust camshaft sub-assembly): Item Specified Condition No. 1 journal 0.027 to 0.064 mm (0.00106 to 0.00252 in.) Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.) Maximum Oil Clearance (for intake camshaft sub-assembly): Item Specified Condition No. 1 journal 0.085 mm (0.00335 in.) Other journals 0.085 mm (0.00335 in.) Maximum Oil Clearance (for exhaust camshaft sub-assembly): Item Specified Condition No. 1 journal 0.085 mm (0.00335 in.) Other journals 0.085 mm (0.00335 in.) NOTICE: Completely remove the Plastigage after the inspection. HINT: If the oil clearance is more than the maximum, replace the intake camshaft sub-assembly or exhaust camshaft sub-assembly. If necessary, replace the camshaft housing sub-assembly.

*a Plastigage *b No. 1 Journal *c Other Journal

5. INSPECT CHAIN SUB-ASSEMBLY

(a) 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.

*a Measurement Length

(b) Using a vernier caliper, measure the length of 15 links.

Maximum Chain Elongation:

116.30 mm (4.58 in.)

NOTICE:

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

HINT:

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

6. INSPECT OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

(a) 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.

*a Measurement Length

(b) Using a vernier caliper, measure the length of 15 links.

Maximum Chain Elongation:

116.30 mm (4.58 in.)

NOTICE:

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

HINT:

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

7. INSPECT OIL PUMP DRIVE SPROCKET

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

(b) 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):

51.35 mm (2.02 in.)

NOTICE:

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

HINT:

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

8. INSPECT OIL PUMP DRIVE SHAFT SPROCKET

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

(b) 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):

51.35 mm (2.02 in.)

NOTICE:

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

HINT:

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

9. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

(a) Place the chain sub-assembly around the camshaft timing gear assembly.

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

Minimum Gear Diameter (with Chain Sub-assembly):

100.01 mm (3.94 in.)

NOTICE:

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

HINT:

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

10. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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

(b) 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):

100.01 mm (3.94 in.)

NOTICE:

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

HINT:

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

11. INSPECT CRANKSHAFT TIMING SPROCKET

(a) Place the chain sub-assembly around the crankshaft timing sprocket.

(b) Using a vernier caliper, measure the diameter of the crankshaft timing sprocket and chain sub-assembly.

Minimum Sprocket Diameter (with Chain Sub-assembly):

51.35 mm (2.02 in.)

NOTICE:

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

HINT:

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

12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Push the plunger and check that it moves smoothly. HINT: If the plunger does not move smoothly, replace the No. 1 chain tensioner assembly.

*a Plunger

13. INSPECT CHAIN TENSIONER SLIPPER

(a) Using a vernier caliper, measure the wear depth of the chain tensioner slipper. Maximum Depth: 1.0 mm (0.0394 in.) HINT: If the depth is more than the maximum, replace the chain tensioner slipper.

*a Depth

14. INSPECT NO. 1 CHAIN VIBRATION DAMPER

(a) Using a vernier caliper, measure the wear depth of the No. 1 chain vibration damper. Maximum Depth: 1.0 mm (0.0394 in.) HINT: If the depth is more than the maximum, replace the No. 1 chain vibration damper.

*a Depth

15. INSPECT CYLINDER HEAD SET BOLT

(a) for 140 mm cylinder head set bolt:

(1) Using a vernier caliper, measure the diameter of the threads at the measurement point. Standard Diameter: 10.7 to 10.9 mm (0.421 to 0.429 in.) Minimum Diameter: 10.6 mm (0.417 in.) Measurement Point (Distance from the Seat): 105 mm (4.13 in.) HINT: 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.

*a Measurement Point *b 105 mm (4.13 in.)

(b) for 130 mm cylinder head set bolt:

(1) Using a vernier caliper, measure the diameter of the threads at the measurement point. Standard Diameter: 9.7 to 9.9 mm (0.382 to 0.390 in.) Minimum Diameter: 9.6 mm (0.378 in.) Measurement Point (Distance from the Seat): 115 mm (4.53 in.) HINT: 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.

*a Measurement Point *b 115 mm (4.53 in.)

16. INSPECT EXHAUST MANIFOLD (TWC: Front Catalyst)

(a) Using a precision straightedge and feeler gauge, check the surface that contacts the cylinder head sub-assembly for warpage. Maximum Warpage: 0.7 mm (0.0276 in.) HINT: If the warpage is more than the maximum, replace the exhaust manifold (TWC: Front Catalyst).

17. INSPECT OIL NOZZLE VALVE SUB-ASSEMBLY

(a) Using a piece of wire, check that the check valve is not stuck.

*a	1 mm (0.0394 in.)
*b	5 mm (0.197 in.)
*c	Check Valve
*d	Wire
	Move the wire in this direction.
	Movement of Check Valve

(b) Connect a hose to the oil nozzle valve sub-assembly

*a Hose

(c) Check that air does not leak from the port (B) when blowing air into the port (A).

HINT:

If air leaks from the port (B), replace the oil nozzle valve sub-assembly with a new one.

(d) With the check valve depressed using a piece of wire, check that air flows from the port (B) when blowing air into the port (A).

*a	Hose
	Move the wire in this direction.
	Movement of Check Valve

HINT:

If air does not flow from the port (B), replace the oil nozzle valve sub-assembly with a new one.

(e) Disconnect the hose from the oil nozzle valve sub-assembly.