INSPECT CYLINDER HEAD SET BOLT

INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

INSPECT VALVE LASH ADJUSTER ASSEMBLY

INSPECT CAMSHAFT

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

INSPECT CHAIN SUB-ASSEMBLY

INSPECT NO. 2 CHAIN SUB-ASSEMBLY

INSPECT CRANKSHAFT TIMING SPROCKET

INSPECT NO. 1 IDLE GEAR

INSPECT NO. 1 IDLE GEAR SHAFT OIL CLEARANCE

INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY

INSPECT CHAIN TENSIONER SLIPPER

INSPECT NO. 1 CHAIN VIBRATION DAMPER

INSPECT NO. 2 CHAIN VIBRATION DAMPER

INSPECT CAMSHAFT THRUST CLEARANCE

INSPECT CAMSHAFT OIL CLEARANCE

INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY

INSPECT INTAKE MANIFOLD FOR FLATNESS

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

• Standard length:
• 141.3 to 142.7 mm (5.56 to 5.62 in.)

• Maximum length:
• 143.7 mm (5.66 in.)

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

Using a vernier caliper, measure the diameter of the elongated thread at the narrowest visible area.

• Standard diameter:
• 10.73 to 10.97 mm (0.422 to 0.432 in.)

• Minimum diameter:
• 10.40 mm (0.409 in.)

If the diameter is less than the minimum, replace the cylinder head set bolt.

• HINT:

• If a visual check reveals no excessively thin areas, check the center of the bolt (refer to illustration) and find the area that has the smallest diameter.

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

If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.

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

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

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

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.

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

• OK:
• Plunger is very difficult to move.

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

Inspect the camshaft runout.

Using a micrometer, measure the cam lobe height.

• Standard Cam Lobe Height:

• Item	Specified Condition
  Intake	43.890 to 43.990 mm (1.728 to 1.732 in.)
  Exhaust	44.262 to 44.362 mm (1.743 to 1.747 in.)

• Minimum Cam Lobe Height:

• Item	Specified Condition
  Intake	43.840 mm (1.726 in.)
  Exhaust	44.212 mm (1.741 in.)

Using a micrometer, measure the journal diameter.

• Standard Journal Diameter:

• Item	Specified Condition
  No. 1 journal	35.946 to 35.960 mm (1.4152 to 1.4157 in.)
  Other journals	25.959 to 25.975 mm (1.0221 to 1.0226 in.)

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

Fix the camshaft in place.

• NOTICE:

• Be careful not to damage the camshaft.

Put the camshaft timing gear assembly and camshaft together by aligning the pin hole and straight pin.

Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

• NOTICE:

• Be sure not to turn the camshaft timing gear assembly in the retard direction.

Check that there is no clearance between the camshaft timing gear assembly flange and camshaft.

Tighten the flange bolt while holding the camshaft.

• Torque:
• 100 N*m{ 1020 kgf*cm, 74 ft.*lbf}

Check the lock of the camshaft timing gear assembly.

Release the lock pin.

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

Text in Illustration

*1	Advance Side Path
*2	Retard Side Path
*3	Open
*4	Close
	Rubber
	Vinyl Tape

• HINT:

• The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece.

Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path as shown in the illustration.

Apply air at approximately 200 kPa (2.0 kgf/cm², 28 psi) to the 2 open paths.

Text in Illustration

*1	Advance Side Path
*2	Retard Side Path

• CAUTION:

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

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

Text in Illustration

*1	Advance Side Path
*2	Retard Side Path
*3	Hold Pressure
*4	Decompress

• HINT:

• This operation releases the lock pin at the most retarded position.

When the camshaft timing gear assembly reaches the most advanced position, release the air pressure first from the retard side path and next from the advance side path.

• NOTICE:

• Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

Check for smooth rotation.

Check the lock in the most retarded position.

Remove the flange bolt and camshaft timing gear assembly.

• NOTICE:

Fix the camshaft in place.

• NOTICE:

• Be careful not to damage the camshaft.

Put the camshaft timing exhaust gear assembly and camshaft together by aligning the pin hole and straight pin.

Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

• NOTICE:

• Be sure not to turn the camshaft timing exhaust gear in the advanced direction.

Check that there is no clearance between the gear flange and camshaft.

Tighten the flange bolt while holding the camshaft.

• Torque:
• 100 N*m{ 1020 kgf*cm, 74 ft.*lbf}

Check the camshaft timing exhaust gear lock.

Release the lock pin.

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

Text in Illustration

*1	Advance Side Path
*2	Retard Side Path
*3	Open
*4	Close
	Rubber
	Vinyl Tape

• HINT:

• The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece.

Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path as shown in the illustration.

Apply air at approximately 200 kPa (2.0 kgf/cm², 28 psi) to the 2 open paths (the advance side path and retard side path).

Text in Illustration

*1	Advance Side Path
*2	Retard Side Path

• CAUTION:

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

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

Text in Illustration

*1	Advance Side Path
*2	Retard Side Path
*3	Hold Pressure
*4	Decompress

• HINT:

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

When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure first from the advance side path, and then release the air pressure from the retard side path.

• NOTICE:

• 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.

Check for smooth rotation.

Check the lock at the most advanced position.

Remove the flange bolt and camshaft timing exhaust gear assembly.

• NOTICE:

Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33 lbf) and measure the length of the chain using a vernier caliper.

• Maximum chain elongation:
• 136.9 mm (5.39 in.)

• HINT:

• Perform the measurement at 3 random places.

If a measurement is more than the maximum, replace the chain sub-assembly.

Using a spring scale, pull the No. 2 chain with a force of 147 N (15 kgf, 33 lbf) and measure the length of the No. 2 chain using a vernier caliper.

• Maximum chain elongation:
• 137.6 mm (5.42 in.)

• HINT:

• Perform the measurement at 3 random places.

If a measurement is more than the maximum, replace the No. 2 chain sub-assembly.

Wrap the chain around the sprocket.

Using a vernier caliper, measure the crankshaft timing sprocket diameter with the chain.

• Minimum gear diameter (with chain):
• 61.0 mm (2.40 in.)

• HINT:

• The vernier caliper must contact the chain rollers for the measurement.

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

Wrap the chain around the gear.

Using a vernier caliper, measure the No. 1 idle gear diameter with the chain.

• Minimum gear diameter (with chain):
• 61.0 mm (2.40 in.)

• HINT:

• The vernier caliper must contact the chain rollers for the measurement.

If the diameter is less than the minimum, replace the chain and No. 1 idle gear.

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

• Standard idle gear shaft diameter:
• 22.987 to 23.000 mm (0.905 to 0.906 in.)

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

• Standard idle gear inside diameter:
• 23.02 to 23.03 mm (0.906 to 0.907 in.)

Subtract the idle gear shaft diameter measurement from the idle gear 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.)

If the shaft oil clearance is more than the maximum, replace the idle gear shaft and idle gear.

Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly.

If necessary, replace the No. 1 chain tensioner.

Check that the plunger moves smoothly.

Measure the depth of wear of the chain tensioner.

• Maximum depth:
• 1.0 mm (0.0394 in.)

If the depth is more than the maximum, replace the No. 2 chain tensioner.

Check that the plunger moves smoothly.

Measure the depth of wear of the chain tensioner.

• Maximum depth:
• 1.0 mm (0.0394 in.)

If the depth is more than the maximum, replace the No. 3 chain tensioner.

Measure the depth of wear of the chain tensioner slipper.

• Maximum depth:
• 1.0 mm (0.0394 in.)

If the depth is more than the maximum, replace the chain tensioner slipper.

Measure the depth of wear of the No. 1 chain vibration damper.

• Maximum depth:
• 1.0 mm (0.0394 in.)

If the depth is more than the maximum, replace the No. 1 chain vibration damper.

Measure the depth of wear of the No. 2 chain vibration damper.

• Maximum depth:
• 1.0 mm (0.0394 in.)

If the depth is more than the maximum, replace the No. 2 chain vibration damper.

Install the camshafts ().

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

• Standard thrust clearance:
• 0.08 to 0.13 mm (0.00315 to 0.00512 in.)

• Maximum thrust clearance:
• 0.15 mm (0.00591 in.)

If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly.

If the thrust surface is damaged, replace the camshaft.

Clean the camshaft bearing caps, camshaft housing and camshaft journals.

Place the camshafts on the camshaft housing.

Lay a strip of Plastigage across each camshaft journal.

Install the camshaft bearing caps ().

• NOTICE:

• Do not turn the camshaft.

Remove the camshaft bearing caps ().

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	0.09 mm (0.00354 in.)

If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the camshaft housing.

Using a precision straightedge and feeler gauge, measure the warpage of the surface which contacts the cylinder head.

• Maximum warpage:
• 0.70 mm (0.0276 in.)

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

Using a precision straightedge and feeler gauge, measure the warpage of the surfaces which contact the cylinder head and intake air surge tank.

• Maximum Warpage:

• Item	Specified Condition
  Intake air surge tank side	0.80 mm (0.0315 in.)
  Cylinder head side	0.20 mm (0.00787 in.)

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