Engine Unit Inspection

Using a vernier caliper, measure the diameter of the elongated thread at the measuring point.

Measuring point:

94 mm (3.70 in.) for intake side bolt

89 mm (3.50 in.) for exhaust side bolt

Standard diameter:

10.85 to 11.00 mm (0.427 to 0.433 in.)

Minimum diameter:

10.6 mm (0.417 in.)

HINT:

If a visual check reveals no excessively thin areas, check the center of the bolt (see 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 valve rocker arm.

Place the lash adjuster into a container full of new engine oil.

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

SST

09276-75010

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

Check the movement of the plunger and bleed air.

OK:

Plunger moves up and down.

NOTICE:

When bleeding high-pressure air from the compression 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 with your fingers.

OK:

Plunger can be pressed 3 times.

Inspect the camshaft for runout.

1. Place the camshaft on V-blocks.
   

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

   Maximum circle runout:

   0.04 mm (0.00157 in.)
   

   If the circle runout is more than the maximum, replace the camshaft sub-assembly.
   

   HINT:

   Check the oil clearance after replacing the camshaft.

Using a micrometer, measure the cam lobe height.

Standard Cam Lobe Height:

Item	Specified Condition
Intake	44.291 to 44.441 mm (1.744 to 1.750 in.)
Exhaust	44.196 to 44.346 mm (1.740 to 1.746 in.)

Minimum Cam Lobe Height:

Item	Specified Condition
Intake	44.241 mm (1.742 in.)
Exhaust	44.146 mm (1.738 in.)

Using a micrometer, measure the journal diameter.

Standard Journal Diameter:

Item	Specified Condition
No. 1 journal	29.956 to 29.970 mm (1.179 to 1.180 in.)
Other journals	25.959 to 25.975 mm (1.022 to 1.023 in.)

Clean the bearing caps, camshaft housing and camshaft journals.

Place the camshafts on the camshaft housing.

Lay a strip of Plastigage across each of the camshaft journals.

Install the camshaft bearing caps (Click here).

NOTICE:

Do not turn the camshaft.

Install the camshaft housing (Click here).

NOTICE:

Do not turn the camshaft.

Remove the camshaft bearing caps (Click here).

Measure the Plastigage at its widest point.

Standard Oil Clearance:

Item	Specified Condition
No. 1 journal	0.030 to 0.065 mm (0.00118 to 0.00256 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.)

Install the camshaft bearing caps (Click here).

HINT:

Only install the intake camshaft.

Install the camshaft housing (Click here).

Apply a light coat of engine oil to the camshaft and camshaft timing gear.

Using the hexagonal portion of the camshaft, align and attach the knock pin of the camshaft with the pin hole of the camshaft timing gear.

NOTICE:

1. Do not forcefully push on the camshaft timing gear. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing gear.
   


2. Do not loosen or remove the 3 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the camshaft timing gear assembly with a new one.
   

Apply a light coat of engine oil to the threads and under the head of the bolt.

Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing gear with the bolt.

Torque:

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

Text in Illustration

*a	Hold
	Turn

Remove the camshaft bearing caps (Click here).

Check the lock of the camshaft timing gear.

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

   NOTICE:

   Be careful not to damage the camshaft.

Release the lock pin.

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

2. Break through the tape of the advance side path and retard side path as shown in the illustration.
   

   Text in Illustration

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





3. Apply approximately 200 kPa (2.0 kgf/cm², 29 psi) of air pressure to the two broken paths.
   

   Text in Illustration

   *1	Advance Side Path
   *2	Retard Side Path

   NOTICE:

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





4. Check that the camshaft timing gear revolves 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	Decompress
   *4	Hold Pressure

   HINT:

   This operation releases the lock pin for the most retarded position.

5. When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path, in that order.
   

   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.

1. Turn the camshaft timing gear within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.
   

   NOTICE:

   Do not use air pressure to perform the smooth rotation check.

Check the lock in the most retarded position.

1. Confirm that the camshaft timing gear is locked at the most retarded position.
   

Install the camshaft bearing caps (Click here).

HINT:

Only install the intake camshaft.

Install the camshaft housing (Click here).

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

Text in Illustration

*a	Hold
	Turn

Remove the camshaft bearing caps (Click here).

Remove the flange bolt and camshaft timing gear.

Install the camshaft bearing caps (Click here).

HINT:

Only install the exhaust camshaft.

Install the camshaft housing (Click here).

Apply a light coat of engine oil to the camshaft and camshaft timing exhaust gear.

Using the hexagonal portion of the camshaft, align and attach the knock pin of the camshaft with the pin hole of the camshaft timing exhaust gear.

NOTICE:

1. Do not forcefully push on the camshaft timing exhaust gear. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing exhaust gear.
   


2. Do not loosen or remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the camshaft timing exhaust gear assembly with a new one.
   

Apply a light coat of engine oil to the threads and under the head of the bolt.

Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing exhaust gear with the bolt.

Torque:

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

Text in Illustration

*a	Hold
	Turn

Remove the camshaft bearing caps (Click here).

Check the camshaft timing exhaust gear lock.

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

Release the lock pin.

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

2. Break through the tape of the advance side path and retard side path as shown in the illustration.
   

   Text in Illustration

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





3. Apply approximately 200 kPa (2.0 kgf/cm², 29 psi) of air pressure to the two broken paths (the advance side path and the retard side path).
   

   Text in Illustration

   *1	Advance Side Path
   *2	Retard Side Path

   NOTICE:

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





4. Check that the camshaft timing exhaust gear turns 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	Decompress
   *4	Hold Pressure

   HINT:

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

5. When the camshaft timing exhaust gear 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.
   

   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 may abruptly shift in the advance direction and break the lock pin or other parts.

Check for smooth rotation.

1. Turn the camshaft timing exhaust gear within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.
   

   NOTICE:

   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.

Check the lock at the most advanced position.

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

Install the camshaft bearing caps (Click here).

HINT:

Only install the exhaust camshaft.

Install the camshaft housing (Click here).

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

Text in Illustration

*a	Hold
	Turn

Remove the camshaft bearing caps (Click here).

Remove the flange bolt and camshaft timing exhaust gear.

Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.

Using a vernier caliper, measure the length of 15 pins.

Maximum chain elongation:

136.9 mm (5.39 in.)

HINT:

Perform the measurement at 3 random places.

Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.

Using a vernier caliper, measure the length of 15 pins.

Maximum chain elongation:

137.6 mm (5.42 in.)

HINT:

Perform the measurement at 3 random places.

Wrap the chain around the sprocket.

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

Minimum sprocket diameter (with chain):

61.4 mm (2.42 in.)

HINT:

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

Wrap the chain around the sprocket.

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

Minimum sprocket diameter (with chain):

61.4 mm (2.42 in.)

HINT:

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

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

Check that the plunger moves smoothly.

Measure the worn depth of the chain tensioner.

Maximum depth:

0.9 mm (0.0354 in.)

Check that the plunger moves smoothly.

Measure the worn depth of the chain tensioner.

Maximum depth:

0.9 mm (0.0354 in.)

for LH:
Measure the worn depth of the chain tensioner slipper.

Maximum depth:

1.0 mm (0.0394 in.)

for RH:
Measure the worn depth of the chain tensioner slipper.

Maximum depth:

1.0 mm (0.0394 in.)

for LH:
Measure the worn depth of the chain vibration damper.

Maximum depth:

1.0 mm (0.0394 in.)

for RH:
Measure the worn depth of the chain vibration damper.

Maximum depth:

1.0 mm (0.0394 in.)

Using a precision straightedge and feeler gauge, measure the warpage of the surface where the exhaust manifold LH contacts the cylinder head.

Maximum warpage:

0.7 mm (0.0276 in.)

Using a precision straightedge and feeler gauge, measure the warpage of the surface where the exhaust manifold RH contacts the cylinder head.

Maximum warpage:

0.7 mm (0.0276 in.)