Part 1

ENGINE UNIT

COMPONENTS:

COMPONENTS:

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COMPONENTS:

COMPONENTS:

COMPONENTS:

INSPECTION (STEPS 1-13)





1. INSPECT CHAIN SUB-ASSEMBLY
a. Pull the chain with a force of 147 N (15 kgf, 33 lbs.) as shown in the illustration.
b. Using vernier calipers, measure the length of 16 links.
Maximum chain elongation: 147.5 mm (5.807 inch)
If the elongation is greater than the maximum, replace the chain.

NOTICE: Perform the same measurement by pulling at random in 3 or more places to obtain an average.





2. INSPECT NO. 2 CHAIN SUB-ASSEMBLY
a. Pull the chain with a force of 147 N (15 kgf, 33 lbs.) as shown in the illustration.
b. Using vernier calipers, measure the length of 16 links.
Maximum chain elongation: 123.6 mm (4.866 inch)
If the elongation is greater than the maximum, replace the chain.

NOTICE: Perform the same measurement by pulling at random in 3 or more places to obtain an average.





3. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY
a. Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly.





4. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
a. Move the stopper plate downward to release the lock. Push the plunger and check that it moves smoothly.





5. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
a. Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip.
Minimum distance: 1.0 mm (0.039 inch)
If the distance is less than the minimum, replace the sprocket.

HINT: If the worn area is too small or difficult to distinguish from a normal area, perform steps (b) and (c).

b. Wrap the chain around the sprocket.
c. Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain): 113.8 mm (4.480 inch)

HINT:
^ The vernier calipers must contact the chain rollers for the measurement.
^ If the diameter is less than the minimum, replace the chain and sprocket.





6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
a. Measure the distance between the most worn out timing gear tip and the beginning of the worn area below the tip.
Minimum distance: 1.0 mm (0.039 inch)
If the distance is less than the minimum, replace the timing gear.

HINT: If the worn area is too small or difficult to distinguish from a normal area, perform steps (b) and (c).

b. Wrap the chain around the timing gear.
c. Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain): 113.8 mm (4.480 inch)

HINT:
^ The vernier calipers must contact the chain rollers for the measurement.
^ If the diameter is less than the minimum, replace the chain and timing gear.





7. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
a. Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip.
Minimum distance: 1.0 mm (0.039 inch)
If the distance is less than the minimum, replace the sprocket.

HINT: If the worn area is too small or difficult to distinguish from a normal area, perform steps (b) and (c).

b. Wrap the chain around the drive sprocket.
c. Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain): 59.4 mm (2.338 inch)

HINT:
^ The vernier calipers must contact the chain rollers for the measurement.
^ If the diameter is less than the minimum, replace the chain and sprocket.





8. INSPECT CHAIN TENSIONER SLIPPER
a. Using vernier calipers, measure the tensioner slipper wear.
Maximum wear: 2.0 mm (0.079 inch)
If the wear is greater than the maximum, replace the tensioner slipper.





9. INSPECT NO. 1 CHAIN VIBRATION DAMPER
a. Using vernier calipers, measure the vibration damper wear.
Maximum wear: 2.0 mm (0.079 inch)
If the wear is greater than the maximum, replace the vibration damper.





10. INSPECT TIMING CHAIN GUIDE
a. Using vernier calipers, measure the chain guide wear.
Maximum wear: 0.5 mm (0.020 inch)
If the wear is greater than the maximum, replace the timing chain guide.





11. INSPECT NO. 2 CRANKSHAFT TIMING SPROCKET
a. Wrap the chain around the sprocket.
b. Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain): 96.7 mm (3.807 inch)

HINT: The vernier calipers must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket.





12. INSPECT BALANCE SHAFT DRIVE GEAR SUB ASSEMBLY
a. Wrap the chain around the sprocket.
b. Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (with chain): 75.9 mm (2.988 inch)

HINT: The vernier calipers must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket.





13. INSPECT NO. 2 CHAIN VIBRATION DAMPER
a. Using vernier calipers, measure the vibration damper No. 2 wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than the maximum, replace the vibration damper.