Part 2

ENGINE UNIT

COMPONENTS (Part 1) (for Bank 1):

COMPONENTS (Part 2) (for Bank 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4) (for 2WD):

COMPONENTS (Part 5) (for 4WD):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8) (for Bank 1):

COMPONENTS (Part 9) (for Bank 2):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

COMPONENTS (Part 12):

INSPECTION Continued

13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Check that the plunger moves smoothly.
(b) Measure the worn depth of the chain tensioner.
Maximum depth: 0.9 mm (0.035 in.)
If the depth is greater than the maximum, replace the chain tensioner.

14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Check that the plunger moves smoothly.
(b) Measure the worn depth of the chain tensioner.
Maximum depth: 0.9 mm (0.035 in.)
If the depth is greater than the maximum, replace the chain tensioner.

15. INSPECT CHAIN TENSIONER SLIPPER
(a) Measure the worn depth of the chain tensioner slipper.
Maximum depth: 1.0 mm (0.039 in.)
If the depth is greater than the maximum, replace the chain tensioner slipper.

16. INSPECT NO. 1 CHAIN VIBRATION DAMPER
(a) Measure the worn depth of the chain vibration damper.
Maximum depth: 1.0 mm (0.039 in.)
If the depth is greater than the maximum, replace the chain vibration damper.

17. INSPECT NO. 2 CHAIN VIBRATION DAMPER
(a) Measure the worn depth of the chain vibration damper.
Maximum depth: 1.0 mm (0.039 in.)
If the depth is greater than the maximum, replace the chain vibration damper.

18. INSPECT CYLINDER HEAD SUB-ASSEMBLY

(a) Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces of the cylinder block and manifolds.

Standard warpage:

Maximum warpage:

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

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

19. INSPECT INTAKE VALVE

(a) Using a micrometer, measure the diameter of the valve stem.
Standard valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 in.)

(b) Using a vernier caliper, measure the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.0394 in.)
Minimum margin thickness: 0.50 mm (0.0197 in.)
If the margin thickness is less than the minimum, replace the intake valve.

(c) Using a vernier caliper, measure the valve's overall length.
Standard overall length: 105.85 mm (4.1673 in.)
Minimum overall length: 105.35 mm (4.1476 in.)
If the overall length is less than the minimum, replace the intake valve.

20. INSPECT EXHAUST VALVE

(a) Using a micrometer, measure the diameter of the valve stem.
Standard valve stem diameter: 5.465 to 5.480 mm (0.2151 to 0.2157 in.)

(c) Using a vernier caliper, measure the valve's overall length.
Standard overall length: 110.40 mm (4.3464 in.)
Minimum overall length: 109.90 mm (4.3268 in.)
If the overall length is less than the minimum, replace the exhaust valve.

21. INSPECT INTAKE VALVE SEAT
(a) Apply a light coat of Prussian blue to the valve face.
(b) Lightly press the valve face against the valve seat.
(c) Check the valve face and valve seat by using the following procedure.
(1) If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.
(2) If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat.
(3) Check that the valve seat contacts in the middle of the valve face with the width between 1.1 and 1.5 mm (0.043 and 0.059 in.).

22. INSPECT EXHAUST VALVE SEAT
(a) Apply a light coat of Prussian blue to the valve face.
(b) Lightly press the valve face against the valve seat.
(c) Check the valve face and valve seat by using the following procedure.
(1) If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.
(2) If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat.
(3) Check that the valve seat contacts in the middle of the valve face with the width between 1.3 and 1.7 mm (0.051 and 0.067 in.).

23. INSPECT INNER COMPRESSION SPRING

(a) Using a vernier caliper, measure the free length of the inner compression spring.
Standard free length: 51.70 mm (2.0354 in.)
If the free length is not as specified, replace the spring.

(b) Using a steel square, measure the deviation of the inner compression spring.
Maximum deviation: 1.0 mm (0.039 in.)
Maximum angle (reference): 2°
If the deviation is greater than the maximum, replace the spring.

24. INSPECT VALVE GUIDE BUSH OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the guide bush.
Standard bush inside diameter: 5.51 to 5.53 mm (0.2169 to 0.2177 in.)
(b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.

Standard oil clearance:

Maximum oil clearance:

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

25. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Inspect the bank 1 camshafts.
(1) Install the bank 1 camshafts.
(2) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
Maximum thrust clearance: 0.15 mm (0.0059 in.)
If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.
(b) Inspect the bank 2 camshafts.
(1) Install the bank 2 camshafts.
(2) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
Maximum thrust clearance: 0.15 mm (0.006 in.)
If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

26. INSPECT CAMSHAFT OIL CLEARANCE

(a) Clean the bearing caps, camshaft housing and camshaft journals.
(b) Place the camshafts on the camshaft housing.
(c) Lay a strip of Plastigage across each of the camshaft journals.
(d) Install the bearing caps.

NOTICE: Do not turn the camshaft.

(e) Remove the bearing caps.

(f) Measure the Plastigage at its widest point.

Standard oil clearance:

Maximum oil clearance:

If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.
(g) Clean the bearing caps, camshaft housing and camshaft journals.
(h) Place the camshafts on the camshaft housing.

(i) Lay a strip of Plastigage across each of the camshaft journals.
(j) Install the bearing caps.

NOTICE: Do not turn the camshaft.

(k) Remove the bearing caps.

(l) Measure the Plastigage at its widest point.

Standard oil clearance:

Maximum oil clearance:

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

27. INSPECT CYLINDER BLOCK FOR WARPAGE

(a) Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.
Maximum warpage: 0.07 mm (0.0028 in.)
If the warpage is greater than the maximum, replace the cylinder block.

(b) Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all 6 cylinders.
If necessary, replace the cylinder block.

28. INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
Standard diameter: 94.000 to 94.012 mm (3.7008 to 3.7013 in.)
Maximum diameter: 94.200 mm (3.7087 in.)
If the diameter is greater than the maximum, replace the cylinder block.

29. INSPECT PISTON SUB-ASSEMBLY WITH PIN
(a) Using a micrometer, measure the piston diameter at a right angle to the piston center line where the distance from the bottom edge of the piston is as specified.
Distance: 9.1 mm (0.36 in.)
Standard diameter: 93.960 to 93.980 mm (3.6992 to 3.6999 in.)
Maximum diameter: 93.830 mm (3.6941 in.)

30. INSPECT PISTON OIL CLEARANCE
(a) Measure the cylinder bore diameter in the thrust direction.
(b) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.020 to 0.052 mm (0.0008 to 0.0020 in.)
Maximum oil clearance: 0.370 mm (0.0146 in.)
If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.

31. INSPECT RING GROOVE CLEARANCE
(a) Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

Standard ring groove clearance:

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

32. INSPECT PISTON RING END GAP

(a) Insert the piston ring into the cylinder bore.
(b) 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.

Standard end gap:

Maximum end gap:

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

33. INSPECT PISTON PIN OIL CLEARANCE

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

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

Standard piston pin hole inside diameter:

Standard piston pin diameter:

(d) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement.
Standard oil clearance: -0.002 to 0.004 mm (-0.00007 to 0.0001 in.)
Maximum oil clearance: 0.015 mm (0.0006 in.)

HINT: If the oil clearance is greater than the maximum, replace the piston and piston pin as a set.

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

Standard bush inside diameter:

(f) Subtract the piston pin diameter measurement from the bush inside diameter measurement.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.)
Maximum oil clearance: 0.03 mm (0.0012 in.)

HINT: If the oil clearance is greater than the maximum, replace the bush. If necessary, replace the connecting rod and piston pin as a set.

34. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) Using a rod aligner and feeler gauge, check the connecting rod alignment.

(1) Check for bend.
Maximum bend: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If the bend is greater than the maximum, replace the connecting rod.

(2) Check for twist.
Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If the twist is greater than the maximum, replace the connecting rod.

35. INSPECT CONNECTING ROD BOLT
(a) Using a vernier caliper, measure the tension portion diameter of the bolt.
Standard diameter: 8.5 to 8.6 mm (0.335 to 0.339 in.)
Minimum diameter: 8.3 mm (0.327 in.)
If the diameter is less than the minimum, replace the bolt.

36. INSPECT CRANKSHAFT

(a) Inspect for circle runout.
(1) Place the crankshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than the maximum, replace the crankshaft.

(b) Inspect the main journals.
(1) Using a micrometer, measure the diameter of each main journal.
Standard journal diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 in.)
If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.
(2) Check each main journal for taper and out-of-round as shown in the illustration.
Maximum taper and out-of-round: 0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.

(c) Inspect the crank pin.
(1) Using a micrometer, measure the diameter of each crank pin.
Standard crank pin diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 in.)
If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.
(2) Check each crank pin for taper and out-of-round as shown in the illustration.
Maximum taper and out-of-round: 0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than the maximum, replace the crankshaft.

37. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using a vernier caliper, measure the minimum diameter of the elongated thread at the measuring point.
Standard diameter: 10.8 to 11.0 mm (0.4252 to 0.4331 in.)
Minimum diameter: 10.70 mm (0.4213 in.)
If the diameter is less than the minimum, replace the bolt.