INSPECT ENGINE BALANCER ASSEMBLY THRUST CLEARANCE

INSPECT CHAIN SUB-ASSEMBLY

INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

INSPECT CAMSHAFT TIMING SPROCKET

INSPECT CRANKSHAFT TIMING SPROCKET

INSPECT CHAIN TENSIONER SLIPPER

INSPECT NO. 1 CHAIN VIBRATION DAMPER

INSPECT CYLINDER HEAD SET BOLT

INSPECT VALVE ROCKER ARM SUB-ASSEMBLY

INSPECT VALVE LASH ADJUSTER ASSEMBLY

INSPECT CYLINDER HEAD SUB-ASSEMBLY

INSPECT INTAKE VALVE SEATS

REPAIR INTAKE VALVE SEATS

INSPECT EXHAUST VALVE SEATS

REPAIR EXHAUST VALVE SEATS

INSPECT CAMSHAFT

INSPECT NO. 2 CAMSHAFT

INSPECT CAMSHAFT THRUST CLEARANCE

INSPECT CAMSHAFT OIL CLEARANCE

INSPECT COMPRESSION SPRING

INSPECT INTAKE VALVE

INSPECT EXHAUST VALVE

INSPECT VALVE GUIDE BUSHING

INSPECT CONNECTING ROD THRUST CLEARANCE

INSPECT CONNECTING ROD OIL CLEARANCE

INSPECT CRANKSHAFT THRUST CLEARANCE

INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY

INSPECT CYLINDER BLOCK FOR WARPAGE

INSPECT CYLINDER BORE

INSPECT PISTON DIAMETER

INSPECT PISTON OIL CLEARANCE

INSPECT RING GROOVE CLEARANCE

INSPECT PISTON RING END GAP

INSPECT PISTON PIN OIL CLEARANCE

INSPECT CONNECTING ROD SUB-ASSEMBLY

INSPECT CONNECTING ROD BOLT

INSPECT CRANKSHAFT

INSPECT CRANKSHAFT OIL CLEARANCE

INSPECT CRANKSHAFT BEARING CAP SET BOLT

Install the engine balancer assembly .

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

• Standard thrust clearance:
• 0.09 mm (0.0035 in.)

• Maximum thrust clearance:
• 0.11 mm (0.0043 in.)

If the thrust clearance is greater than the maximum, replace the balance shaft assembly.

Using vernier calipers, measure the length of the bolts from the seat to the end.

• Standard bolt length:

• Item	Length
  Bolt A	38.2 to 39.6 mm (1.504 to 1.559 in.)
  Except bolt A	53.8 to 55.2 mm (2.118 to 2.173 in.)

• Maximum bolt length:

• Item	Length
  Bolt A	40.5 mm (1.595 in.)
  Except bolt A	56 mm (2.205 in.)

If the bolt length is greater than the maximum, replace the bolt.

Pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown in the illustration.

Using vernier calipers, measure the length of 16 links.

• Maximum chain elongation:
• 144.3 mm (5.681 in.)

If the elongation is greater than the maximum, replace the chain.

• NOTICE:

• Perform the measurement at random in 3 or more places to obtain an average.

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 assembly.

Wrap the chain around the sprocket.

Using vernier calipers, measure the sprocket diameter with the chain installed.

• Minimum diameter of sprocket with chain installed:
• 132.6 mm (5.220 in.)

• HINT:

Wrap the chain around the drive sprocket.

Using vernier calipers, measure the sprocket diameter with the chain installed.

• Minimum diameter of sprocket with chain installed:
• 69.1 mm (2.7205 in.)

• HINT:

Using vernier calipers, measure the tensioner slipper wear.

• Maximum wear:
• 1.0 mm (0.039 in.)

If the wear is greater than the maximum, replace the tensioner slipper.

Using vernier calipers, measure the vibration damper wear.

• Maximum wear:
• 1.0 mm (0.039 in.)

If the wear is greater than the maximum, replace the vibration damper.

Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point.

• Standard outside diameter:
• 11.8 to 12.0 mm (0.465 to 0.472 in.)

• Minimum outside diameter:
• 11.20 mm (0.4409 in.)

• HINT:

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

• HINT:

• If the roller does not turn smoothly, replace the valve rocker arm sub-assembly.

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

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

• SST
• 09276-75010

Squeeze the SST and lash adjuster 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 high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the checkball as shown in the illustration. If the checkball is not pressed, air will not bleed.

After bleeding the air, remove the SST. Then quickly and firmly press the plunger with your fingers.

• OK:
• Plunger is very difficult to move.

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

Using a precision straight edge and feeler gauge, measure the warpage of the cylinder block and manifold contact surfaces.

• Maximum warpage:
• 0.05 mm (0.0020 in.)

If the warpage is greater than the maximum, replace the cylinder head.

Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head.

Apply a light coat of prussian blue to the valve face.

Lightly press the valve face against the valve seat.

Check the valve face and valve seat by using the following procedure:

If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.

• NOTICE:

• Keep the lip free from foreign matter.

If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.

Handrub the valve and valve seat with an abrasive compound.

Check the valve seating position.

Apply a light coat of prussian blue to the valve face.

Lightly press the valve face against the valve seat.

Check the valve face and valve seat by using the following procedure:

If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.

• NOTICE:

• Keep the lip free from foreign matter.

If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.

Handrub the valve and valve seat with an abrasive compound.

Check the valve seating position.

Check the camshaft for runout.

Using a micrometer, measure the cam lobe height.

• Standard cam lobe height:
• 37.559 to 37.759 mm (1.47870 to 1.48657 in.)

• Minimum cam lobe height:
• 37.559 mm (1.47870 in.)

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

Using a micrometer, measure the journal diameter.

• Standard journal diameter:
• 26.969 to 26.985 mm (1.06177 to 1.06240 in.)

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

Check the camshaft for runout.

Using a micrometer, measure the cam lobe height.

• Standard cam lobe height:
• 38.270 to 38.470 mm (1.50669 to 1.51456 in.)

• Minimum cam lobe height:
• 38.270 mm (1.50669 in.)

If the cam lobe height is less than the minimum, replace the camshaft. If the journal diameter is not as specified, check the oil clearance.

Using a micrometer, measure the journal diameter.

• Standard journal diameter:
• 26.969 to 26.985 mm (1.06177 to 1.06240 in.)

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

Install the No. 2 camshaft and camshaft .

• Standard thrust clearance:
• 0.035 to 0.160 mm (0.00138 to 0.00630 in.)

• Maximum thrust clearance:
• 0.160 mm (0.00630 in.)

If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

Clean the bearing caps and camshaft journals.

Set the camshafts on the cylinder head.

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

Install the bearing caps .

• NOTICE:

• Do not turn the camshaft.

Remove the bearing caps .

Measure the Plastigage at its widest point.

• Standard journal clearance:
• 0.025 to 0.062 mm (0.00098 to 0.00244 in.)

• Maximum oil clearance:
• 0.062 mm (0.00244 in.)

If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the cylinder head.

Completely remove the Plastigage.

Using vernier calipers, measure the free length of the compression spring.

• Free length:
• 45.90 mm (1.8071 in.)

If the free length is not as specified, replace the spring.

Using a steel square, measure the deviation of the compression spring.

• Maximum deviation:
• 1.5 mm (0.059 in.)

• Maximum angle (reference):
• 2°

If the deviation is greater than the maximum, replace the spring.

Using vernier calipers, measure the overall length of the valve.

• Standard overall length:
• 104.4 mm (4.110 in.)

• Minimum overall length:
• 104.1 mm (4.098 in.)

If the overall length is less than the minimum, replace the valve.

Using a micrometer, measure the diameter of the valve stem.

• Valve stem diameter:
• 5.970 to 5.985 mm (0.23504 to 0.23563 in.)

Using vernier calipers, measure the valve head margin thickness.

• Standard margin thickness:
• 1.40 to 1.60 mm (0.055 to 0.063 in.)

• Minimum margin thickness:
• 0.50 mm (0.0197 in.)

If the overall length is less than the minimum, replace the valve.

Using vernier calipers, measure the overall length of the valve.

• Standard overall length:
• 104.1 mm (4.098 in.)

• Minimum overall length:
• 103.8 mm (4.087 in.)

If the overall length is less than the minimum, replace the valve.

Using a micrometer, measure the diameter of the valve stem.

• Valve stem diameter:
• 5.960 to 5.975 mm (0.23465 to 0.23524 in.)

Using vernier calipers, measure the valve head margin thickness.

• Standard margin thickness:
• 1.36 to 1.56 mm (0.0535 to 0.0614 in.)

• Minimum margin thickness:
• 0.50 mm (0.0197 in.)

If the overall length is less than the minimum, replace the valve.

Using a caliper gauge, measure the inside diameter of the guide bush.

• Bush inside diameter:
• 6.010 to 6.030 mm (0.2366 to 0.2374 in.)

• HINT:

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

Subtract the valve stem diameter measurement (see steps 21 and 22) from the guide bush inside diameter measurement.

• Standard oil clearance:

• 	Clearance
  Intake	0.025 to 0.060 mm (0.0010 to 0.0024 in.)
  Exhaust	0.035 to 0.070 mm (0.0014 to 0.0028 in.)

• Maximum oil clearance:

• 	Clearance
  Intake	0.06 mm (0.0024 in.)
  Exhaust	0.07 mm (0.0028 in.)

• HINT:

• If the clearance is greater than the maximum, replace the valve and guide bush.

Install the connecting rod cap .

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

• Standard thrust clearance:
• 0.10 to 0.45 mm (0.0039 to 0.0177 in.)

• Maximum thrust clearance:
• 0.55 mm (0.0217 in.)

• HINT:

• If the thrust clearance is greater than the maximum, replace one or more connecting rod assembly as necessary. If necessary, replace the crankshaft.

Clean the crank pin and bearing.

Check the crank pin and bearing for pitting and scratches.

Lay a strip of Plastigage on the crank pin.

Install the connecting rod cap .

• NOTICE:

• Do not turn the crankshaft.

Remove the 2 connecting rod cap bolts .

Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

• HINT:

• Keep the lower bearing inserted to the connecting rod cap.

Measure the Plastigage at its widest point.

• Standard oil clearance:
• 0.024 to 0.042 mm (0.0009 to 0.0017 in.)

• Maximum oil clearance:
• 0.066 mm (0.0026 in.)

If the oil clearance is greater than the maximum, replace the bearings. If necessary, grind or replace the crankshaft.

• HINT:

• If using a standard bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the crankshaft and connecting rod, then select the bearing with the same number as the total. There are 5 sizes of standard bearings, marked 1, 2, 3, 4 and 5.

EXAMPLE:

Connecting rod cap "3" + Crankshaft "1" = Total number 4 (Use bearing "4")

• Reference:
• Connecting rod big end inner diameter:

• Mark	Thickness
  1	53.000 to 53.006 mm (2.0866 to 2.0869 in.)
  2	53.006 to 53.012 mm (2.0869 to 2.0871 in.)
  3	53.012 to 53.018 mm (2.0871 to 2.0873 in.)

• Crankshaft pin diameter:

• Mark	Thickness
  0	49.994 to 50.000 mm (1.9683 to 1.9685 in.)
  1	49.988 to 49.994 mm (1.9680 to 1.9683 in.)
  2	49.982 to 49.988 mm (1.9678 to 1.9680 in.)

• Standard sized bearing center wall thickness:

• Mark	Thickness
  1	1.485 to 1.488 mm (0.0585 to 0.0586 in.)
  2	1.488 to 1.491 mm (0.0586 to 0.0587 in.)
  3	1.491 to 1.494 mm (0.0587 to 0.0588 in.)
  4	1.494 to 1.497 mm (0.0588 to 0.0589 in.)
  5	1.497 to 1.500 mm (0.0589 to 0.0591 in.)

Completely remove the Plastigage.

Install the crankshaft bearing cap .

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

• Standard thrust clearance:
• 0.04 to 0.24 mm (0.0016 to 0.0094 in.)

• Maximum thrust clearance:
• 0.30 mm (0.0118 in.)

• HINT:

• If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.

• Thrust washer thickness:
• 1.93 to 1.98 mm (0.0760 to 0.0780 in.)

Check the oil nozzles for damage or clogging.

• HINT:

• If there is damage or clogging, replace the oil nozzle.

Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.

• Maximum warpage:
• 0.05 mm (0.0020 in.)

• HINT:

• If the warpage is greater than the maximum, replace the cylinder block.

Visually check the cylinder for vertical scratches.

• HINT:

• If deep scratches are present, replace the cylinder block.

Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.

• Standard diameter:
• 86.000 to 86.013 mm (3.38582 to 3.38633 in.)

• HINT:

• If the diameter is greater than the standard, replace the cylinder block.

Inspect the cylinder ridge.

• HINT:

• If wear is less than 0.2 mm (0.008 in.), grind the top of the cylinder using a ridge reamer.

Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the bottom edge of the piston is as specified.

• Distance:
• 10 mm (0.39 in.)

• Piston diameter:

• Size	Diameter
  Standard	85.919 to 85.933 mm (3.38263 to 3.38318 in.)

Measure the cylinder bore diameter in the thrust direction.

Subtract the piston diameter measurement from the cylinder bore diameter measurement.

• Standard oil clearance:
• 0.067 to 0.094 mm (0.00264 to 0.00370 in.)

• HINT:

• If the oil clearance is greater than the standard, replace all the pistons. If necessary, replace the cylinder block.

Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

• Ring groove clearance:

• Ring	Clearance
  No. 1	0.11 to 0.15 mm (0.0043 to 0.0059 in.)
  No. 2	0.08 to 0.12 mm (0.0031 to 0.0047 in.)
  Oil	0.03 to 0.07 mm (0.0012 to 0.0028 in.)

• HINT:

• If the clearance is not as specified, replace the piston.

Insert the piston ring into the cylinder bore.

Using a piston, push the piston ring a little beyond the bottom of the ring travel 110 mm (4.33 in.) from the top of the cylinder block.

Using a feeler gauge, measure the end gap.

• Standard end gap:

• Ring	Clearance
  No. 1	0.22 to 0.32 mm (0.0087 to 0.0126 in.)
  No. 2	0.32 to 0.47 mm (0.0126 to 0.0185 in.)
  Oil	0.1 to 0.4 mm (0.0039 to 0.0157 in.)

• Maximum end gap:

• Ring	Clearance
  No. 1	0.32 mm (0.0126 in.)
  No. 2	0.47 mm (0.0185 in.)
  Oil	0.4 mm (0.0157 in.)

• HINT:

• If the end gap is greater than the maximum, replace the piston ring. If the end gap of a new piston ring is greater than the maximum, replace the cylinder block.

Check each mark on the piston, piston pin and connecting rod.

Using a caliper gauge, measure the inside diameter of the piston pin hole.

• Piston pin hole inside diameter:

• Mark	mm (in.)
  A	29.009 to 29.013 (1.14208 to 1.14224)
  B	29.013 to 29.017 (1.14224 to 1.14240)
  C	29.017 to 29.021 (1.14240 to 1.14256)

Using a micrometer, measure the piston pin diameter.

• Piston pin diameter:

• Mark	mm (in.)
  A (White)	29.000 to 29.004 (1.14173 to 1.14189)
  B (Pink)	29.004 to 29.008 (1.14189 to 1.14204)
  C (Blue)	29.008 to 29.012 (1.14204 to 1.14220)

Using a caliper gauge, measure the inside diameter of the connecting rod bush.

• Bushing inside diameter:

• Mark	mm (in.)
  A	29.019 to 29.023 (1.14248 to 1.14264)
  B	29.023 to 29.027 (1.14264 to 1.14279)
  C	29.027 to 29.031 (1.14279 to 1.14295)

Inspect the piston pin oil clearance.

Using a rod aligner and feeler gauge, check the connecting rod alignment.

Check for bend.

• Maximum bend:
• 0.03 mm (0.0012 in.) per 100 mm (3.94 in.)

• HINT:

• If the bend is greater than the maximum, replace the connecting rod sub-assembly.

Check for twist.

• Maximum twist:
• 0.15 mm (0.0059 in.) per 100 mm (3.94 in.)

• HINT:

• If the twist is greater than the maximum, replace the connecting rod sub-assembly.

Using vernier calipers, measure the tension portion diameter of the bolt.

• Standard diameter:
• 8.7 to 8.8 mm (0.343 to 0.346 in.)

• Minimum diameter:
• 8.5 mm (0.335 in.)

• HINT:

• If the diameter is less than the minimum, replace the bolt.

Inspect for circle runout.

Place the crankshaft on V-blocks.

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

• Maximum circle runout:
• 0.04 mm (0.0016 in.)

• HINT:

• If the circle runout is greater than the maximum, replace the crankshaft.

Inspect the main journals.

Inspect the crank pin.

Clean each main journal and bearing.

Check each main journal and bearing for pitting and scratches.

• HINT:

• If the journal or bearing is damaged, replace the bearing.

Place the crankshaft on the cylinder block.

Lay a strip of Plastigage across each journal.

Place the crankshaft bearing cap assembly on the cylinder block.

Install the crankshaft bearing cap bolts .

• NOTICE:

• Do not turn the crankshaft.

Remove the crankshaft bearing cap .

Measure the Plastigage at its widest point.

• Standard oil clearance:

• Bearing Cap	Standard
  No. 3	0.020 to 0.038 mm (0.00079 to 0.00149 in.)
  Others	0.014 to 0.032 mm (0.00055 to 0.00126 in.)

• Maximum oil clearance:
• 0.10 mm (0.0039 in.)

If the oil clearance is greater than the maximum, replace the bearings. If necessary, grind or replace the crankshaft.

• HINT:

• If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then select the bearing with the same number as the total.

• There are 6 sizes of standard bearings, marked 0, 1, 2, 3, 4 and 5.

EXAMPLE:

Cylinder block "2" + Crankshaft "1" = Total number 3 (Use bearing "3")

• Reference:
• Cylinder block main journal bore diameter:

• Mark	Diameter
  0 (No. 3 Journal)	63.000 to 63.006 mm (2.48031 to 2.48055 in.)
  1 (No. 3 Journal)	63.006 to 63.012 mm (2.48055 to 2.48078 in.)
  2 (No. 3 Journal)	63.012 to 63.018 mm (2.48078 to 2.48102 in.)
  1 (Others)	63.000 to 63.006 mm (2.48031 to 2.48055 in.)
  2 (Others)	63.006 to 63.012 mm (2.48055 to 2.48078 in.)
  3 (Others)	63.012 to 63.018 mm (2.48078 to 2.48102 in.)

• Crankshaft journal diameter:

• Mark	Diameter
  0	58.994 to 59.000 mm (2.32259 to 2.32283 in.)
  1	58.988 to 58.994 mm (2.32236 to 2.32259 in.)
  2	58.982 to 58.988 mm (2.32212 to 2.32236 in.)

• Standard sized bearing center wall thickness:

• Mark	Diameter
  0	1.987 to 1.990 mm (0.07823 to 0.07835 in.)
  1	1.990 to 1.993 mm (0.07835 to 0.07846 in.)
  2	1.993 to 1.996 mm (0.07846 to 0.07858 in.)
  3	1.996 to 1.999 mm (0.07858 to 0.07870 in.)
  4	1.999 to 2.002 mm (0.07870 to 0.07881 in.)
  5	2.002 to 2.005 mm (0.07881 to 0.07894 in.)

Completely remove the Plastigage.

Using vernier calipers, measure the minimum diameter of the compressed thread at the measuring point.

• Standard diameter:
• 10.8 to 11.0 mm (0.425 to 0.433 in.)

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

• HINT:

• If the diameter is less than the minimum, replace the bolt.