Inspection [11/2015 - ]: Procedure

INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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.

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INSPECT VALVE LASH ADJUSTER ASSEMBLY

NOTE:

Keep the valve lash adjuster assembly free from dirt and foreign matter.
Only use clean engine oil.

Place the valve lash adjuster assembly into a container fulled 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.

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

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.

NOTE:
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.

HINT:

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

INSPECT CHAIN SUB-ASSEMBLY

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*a	Measurement Length

Using a spring scale, pull the chain sub-assembly 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 links.

Maximum Chain Elongation

Specified Condition
115.2 mm
4.54 in.

NOTE:

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.

INSPECT NO. 2 CHAIN SUB-ASSEMBLY

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*a	Measurement Length

Using a spring scale, pull the No. 2 chain sub-assembly 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 links.

Maximum Chain Elongation

Specified Condition
102.1 mm
4.02 in.

NOTE:

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.

INSPECT OIL PUMP DRIVE GEAR

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

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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)

Specified Condition
48.2 mm
1.90 in.

NOTE:

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

HINT:

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

INSPECT OIL PUMP DRIVE SHAFT GEAR

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

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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)

Specified Condition
48.2 mm
1.90 in.

NOTE:

The vernier caliper must be in contact with the chain 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.

INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

Place the chain sub-assembly around the camshaft timing gear assembly.

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Using a vernier caliper, measure the diameter of the camshaft timing gear assembly and chain sub-assembly.

Minimum Gear Diameter (with Chain Sub-assembly)

Specified Condition
96.8 mm
3.81 in.

NOTE:

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

HINT:

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

INSPECT CAMSHAFT TIMING SPROCKET

Place the chain sub-assembly around the camshaft timing sprocket.

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Using a vernier caliper, measure the diameter of the camshaft timing sprocket and chain sub-assembly.

Minimum Gear Diameter (with Chain Sub-assembly)

Specified Condition
96.8 mm
3.81 in.

NOTE:

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

HINT:

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

INSPECT CRANKSHAFT TIMING SPROCKET

Place the chain sub-assembly around the crankshaft timing sprocket.

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Using a vernier caliper, measure the diameter of the crankshaft timing sprocket and chain sub-assembly.

Minimum Sprocket Diameter (with Chain Sub-assembly)

Specified Condition
51.1 mm
2.01 in.

NOTE:

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

HINT:

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

INSPECT CHAIN TENSIONER SLIPPER

Using a vernier caliper, measure the wear depth of the chain tensioner slipper.

Maximum Depth

Specified Condition
1.0 mm
0.0394 in.

HINT:

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

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Depth

INSPECT NO. 1 CHAIN VIBRATION DAMPER

Using a vernier caliper, measure the wear depth of the No. 1 chain vibration damper.

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Depth

Maximum Depth

Specified Condition
1.0 mm
0.0394 in.

HINT:

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

INSPECT NO. 2 CHAIN VIBRATION DAMPER

Using a vernier caliper, measure the wear depth of the No. 2 chain vibration damper.

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Depth

Maximum Depth

Specified Condition
1.0 mm
0.0394 in.

HINT:

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

INSPECT CHAIN TENSIONER PLATE

Using a vernier caliper, measure the wear depth of the chain tensioner plate.

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Depth

Maximum Depth

Specified Condition
1.0 mm
0.0394 in.

HINT:

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

INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

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

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*a	Raise
*b	Move
*c	Lock

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.

INSPECT CAMSHAFT

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Inspect the camshaft for runout.

Place the camshaft on V-blocks.

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

Maximum Runout

Specified Condition
0.03 mm
0.00118 in.

HINT:

If the runout is more than the maximum, replace the camshaft.

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Inspect the cam lobes.

Using a micrometer, measure the cam lobe height.

Standard Cam Lobe Height

Minimum Cam Lobe Height	Specified Condition
42.766 mm	42.816 to 42.916 mm
1.6837 in.	1.6857 to 1.6896 in.

HINT:

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

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Inspect the camshaft journals.

Using a micrometer, measure the journal diameter.

Standard Journal Diameter

Journal Position	Specified Condition
No. 1	34.449 to 34.465 mm
No. 1	1.3563 to 1.3569 in.
Others	22.949 to 22.965 mm
Others	0.90350 to 0.90413 in.

HINT:

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

See step 19

INSPECT NO. 2 CAMSHAFT

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Inspect the No. 2 camshaft for runout.

Place the No. 2 camshaft on V-blocks.

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

Maximum Runout

Specified Condition
0.03 mm
0.00118 in.

HINT:

If the runout is more than the maximum, replace the No. 2 camshaft.

Inspect the cam lobes.

Using a micrometer, measure the cam lobe height.

Standard Cam Lobe Height

Minimum Cam Lobe Height	Specified Condition
43.294 mm	43.344 to 43.444 mm
1.7045 in.	1.7065 to 1.7104 in.

HINT:

If the cam lobe height is less than the minimum, replace the No. 2 camshaft.

Inspect the camshaft journals.

Using a micrometer, measure the journal diameter.

Standard Journal Diameter

Journal Position	Specified Condition
No. 1	34.449 to 34.465 mm
No. 1	1.3563 to 1.3569 in.
Others	22.949 to 22.965 mm
Others	0.90350 to 0.90413 in.

HINT:

If the journal diameter is not as specified, check the No. 2 camshaft oil clearance.

See step 19

INSPECT CYLINDER HEAD SET BOLT

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

Standard Length

Maximum Length	Specified Condition
149.2 mm	146.8 to 148.2 mm
5.87 in.	5.78 to 5.83 in.

NOTE:

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.)

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

Standard Diameter

Minimum Diameter	Specified Condition
9.4 mm	9.77 to 9.96 mm
0.370 in.	0.385 to 0.392 in.

NOTE:

Diameter measurements should be done at several points.
If the diameter is less than the minimum, 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.

INSPECT CAMSHAFT THRUST CLEARANCE

Clean the camshaft, No. 2 camshaft and camshaft bearing caps.
Place the camshaft, No. 2 camshaft and camshaft housing sub-assembly on the cylinder head.
Install the camshaft bearing caps.
HINT:

See step 19
Install the camshaft housing sub-assembly.
HINT:

See step 21

Using a dial indicator, measure the thrust clearance while moving the camshaft and No. 2 camshaft back and forth.

Standard Thrust Clearance

Maximum Thrust Clearance	Specified Condition
0.17 mm	0.06 to 0.155 mm
0.00669 in.	0.00236 to 0.00610 in.

HINT:

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

INSPECT CAMSHAFT OIL CLEARANCE

Clean the camshaft bearing caps and camshaft journals.
Place the camshaft, No. 2 camshaft and camshaft housing sub-assembly on the cylinder head.

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

*a	Plastigage

Install the camshaft bearing caps.
NOTE:
Do not turn the camshaft.

HINT:

See step 19
Remove the camshaft bearing caps.
HINT:

See step 33

Measure the Plastigage at its widest point.

*a	Plastigage

Standard Oil Clearance

Item	Maximum Oil Clearance	Specified Condition
No. 1 Journal	0.085 mm	0.030 to 0.063 mm
No. 1 Journal	0.00335 in.	0.00118 to 0.00248 in.
Other Journals	0.09 mm	0.035 to 0.072 mm
Other Journals	0.00354 in.	0.00138 to 0.00283 in.

NOTE:

Completely remove the Plastigage after the inspection.

HINT:

If the oil clearance is greater than the maximum, replace the camshaft or No. 2 camshaft. If necessary, replace the cylinder head sub-assembly.

INSPECT EXHAUST MANIFOLD

Using a precision straightedge and feeler gauge, check the surface that contacts the cylinder head sub-assembly for warpage.

Maximum Warpage

Specified Condition
0.7 mm
0.0276 in.

HINT:

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