INSPECT CYLINDER HEAD SET BOLT

INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

INSPECT VALVE LASH ADJUSTER ASSEMBLY

INSPECT CAMSHAFT SUB-ASSEMBLY

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

INSPECT NO. 1 CHAIN SUB-ASSEMBLY

INSPECT NO. 2 CHAIN SUB-ASSEMBLY

INSPECT CRANKSHAFT TIMING SPROCKET RH

INSPECT CRANKSHAFT TIMING SPROCKET LH

INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY

INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY

INSPECT CHAIN TENSIONER SLIPPER LH

INSPECT CHAIN TENSIONER SLIPPER RH

INSPECT NO. 1 CHAIN VIBRATION DAMPER LH

INSPECT NO. 1 CHAIN VIBRATION DAMPER RH

INSPECT EXHAUST MANIFOLD ASSEMBLY LH

INSPECT EXHAUST MANIFOLD ASSEMBLY RH

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 threads around the point indicated in the illustration.

• Distance:

• Item	Specified Condition
  Intake side bolt	103 mm (4.06 in.)
  Exhaust side bolt	108 mm (4.25 in.)

• Standard diameter:
• 10.85 to 11.00 mm (0.427 to 0.433 in.)

• Minimum diameter:
• 10.60 mm (0.417 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 area of the bolt around the point indicated in the 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 into a container full of new engine oil.

Insert the tip of SST into the valve lash adjuster 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 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.

If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster assembly with a new one.

Inspect the camshaft runout.

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.)

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

Using a micrometer, measure the journal diameter.

• Standard Journal Diameter:

• Item	Specified Condition
  No. 1 journal	29.956 to 29.970 mm (1.1793 to 1.1799 in.)
  Other journals	25.959 to 25.975 mm (1.0220 to 1.0226 in.)

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

Install the camshaft bearing cap ().

• HINT:

• Only install the intake camshaft.

Install the camshaft housing ().

• HINT:

• Do not use seal packing when installing the camshaft housing as the installation is temporary.

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

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

• NOTICE:

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.

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 flange bolt.

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

Text in Illustration

*a	Hold
	Turn

Remove the camshaft bearing cap ().

Check the lock of the camshaft timing gear.

Release the lock pin.

Text in Illustration

*1	Advance Side Path
*2	Retard Side Path
*a	Open
*b	Close
	Vinyl Tape

Clean the cam journal with non-residue solvent.

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

Break through the tape over the advance side path. Then break through the tape over the retard side path on the opposite side of the advanced side path as shown in the illustration.

Apply compressed air at approximately 200 kPa (2.0 kgf/cm², 29 psi) to the two paths accessible through the holes in the tape.

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.

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
*a	Decompress
*b	Hold Pressure

• HINT:

• This operation releases the lock pin which holds the timing gear in the most retarded position.

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.

Check the lock at the most retarded position.

Install the camshaft bearing cap ().

• HINT:

• Only install the intake camshaft.

Install the camshaft housing ().

• HINT:

• Do not use seal packing when installing the camshaft housing as the installation is temporary.

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

Text in Illustration

*a	Hold
	Turn

Remove the camshaft bearing cap ().

Remove the flange bolt and camshaft timing gear.

Install the camshaft bearing cap ().

• HINT:

• Only install the exhaust camshaft.

Install the camshaft housing ().

• HINT:

• Do not use seal packing when installing the camshaft housing as the installation is temporary.

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

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

• NOTICE:

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.

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 flange bolt.

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

Text in Illustration

*a	Hold
	Turn

Remove the camshaft bearing cap ().

Check the camshaft timing exhaust gear lock.

Release the lock pin.

Text in Illustration

*1	Advance Side Path
*2	Retard Side Path
*a	Open
*b	Close
	Vinyl Tape

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

Break through the tape over the advance side path. Then break through the tape over the retard side path on the opposite side of the advanced side path as shown in the illustration.

Apply compressed air at approximately 200 kPa (2.0 kgf/cm², 29 psi) to the two paths accessible through the holes in the tape (the advance side path and 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.

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
*a	Hold Pressure
*b	Decompress

• HINT:

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

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.

Check the lock at the most advanced position.

Install the camshaft bearing cap ().

• HINT:

• Only install the exhaust camshaft.

Install the camshaft housing ().

• HINT:

• Do not use seal packing when installing the camshaft housing as the installation is temporary.

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

Text in Illustration

*a	Hold
	Turn

Remove the camshaft bearing cap ().

Remove the flange bolt and camshaft timing exhaust gear.

Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33.1 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.

If the elongation is more than the maximum, replace the No. 1 chain sub-assembly.

Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33.1 lbf).

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.

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

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.

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

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.

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

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.

Check that the plunger moves smoothly.

Measure the worn depth of the chain tensioner.

• Maximum depth:
• 0.9 mm (0.0354 in.)

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

Check that the plunger moves smoothly.

Measure the worn depth of the chain tensioner.

• Maximum depth:
• 0.9 mm (0.0354 in.)

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

Measure the worn depth 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 LH.

Measure the worn depth 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 RH.

Measure the worn depth of the 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 LH.

Measure the worn depth of the 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 RH.

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

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

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

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

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

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