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 VALVE LASH ADJUSTER ASSEMBLY

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

(b) 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

*a Correct *b Incorrect *c Taper Part *d Low Pressure Chamber *e High Pressure Chamber *f Plunger *g Check Ball

(c) Squeeze SST and the valve lash adjuster assembly together to move the plunger up and down 5 to 6 times.

(d) Check the movement of the plunger and bleed the air.

OK:

Plunger moves up and down.

NOTICE:

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.

(e) After bleeding the air, remove SST. Then try to quickly and firmly press the plunger by hand.

OK:

Plunger is very difficult to move.

HINT:

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

3. INSPECT CHAIN SUB-ASSEMBLY

(a) 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:

115.2 mm (4.535 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.

4. INSPECT NO. 2 CHAIN SUB-ASSEMBLY

(a) Pull the No. 2 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:

102.1 mm (4.019 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 No. 2 chain sub-assembly.

5. INSPECT OIL PUMP DRIVE GEAR

(a) Place the No. 2 chain sub-assembly around the oil pump drive gear.

(b) Using a vernier caliper, measure the diameter of the oil pump drive gear and No. 2 chain sub-assembly.

Minimum Gear Diameter (with No. 2 Chain Sub-assembly):

48.2 mm (1.898 in.)

NOTICE:

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

HINT:

If the diameter is less than the minimum, replace the No. 2 chain sub-assembly and oil pump drive gear.

6. INSPECT OIL PUMP DRIVE SHAFT GEAR

(a) Place the No. 2 chain sub-assembly around the oil pump drive shaft gear.

(b) Using a vernier caliper, measure the diameter of the oil pump drive shaft gear and No. 2 chain sub-assembly .

Minimum Gear Diameter (with No. 2 Chain Sub-assembly):

48.2 mm (1.898 in.)

NOTICE:

The vernier caliper must be in contact with the No. 2 chain sub-assembly rollers when measuring.

HINT:

If the diameter is less than the minimum, replace the No. 2 chain sub-assembly and oil pump drive shaft gear.

7. 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):

96.8 mm (3.811 in.)

NOTICE:

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

HINT:

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

8. 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):

96.8 mm (3.811 in.)

NOTICE:

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

HINT:

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

9. 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):

51.1 mm (2.012 in.)

NOTICE:

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

HINT:

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

10. 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

11. 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

12. INSPECT CHAIN TENSIONER PLATE

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

*a Depth

13. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Check that the plunger moves smoothly when the cam is raised with your finger.

*a Raise *b Move *c Locked

(b) Release the cam, then check that the plunger is locked in place by the cam and does not move when pushed with your finger.

HINT:

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

14. INSPECT CAMSHAFT THRUST CLEARANCE

(a) Install the camshaft housing sub-assembly.

Click here

HINT:

Do not use seal packing when installing the camshaft housing sub-assembly, as the installation is temporary.

(b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard Thrust Clearance: 0.06 to 0.155 mm (0.00236 to 0.00610 in.) Maximum Thrust Clearance: 0.17 mm (0.00669 in.) HINT: If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly.

15. INSPECT CYLINDER HEAD SET BOLT

(a) Using a vernier caliper, measure the length of the cylinder head set 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.) NOTICE: 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.

*a Measurement Length *b Measurement Area *c 115 mm (4.53 in.)

(b) Using a vernier caliper, measure the diameter of the threads at several points within the area shown in the illustration.

Standard Diameter:

9.77 to 9.96 mm (0.3846 to 0.3921 in.)

Minimum Diameter:

9.4 mm (0.3701 in.)

16. INSPECT EXHAUST MANIFOLD

(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.