NR Series ENGINE MECHANICAL ENGINE UNIT INSPECTION

Hide Display 13801 1.INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

a.

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.

Hide Display 13750 2.INSPECT VALVE LASH ADJUSTER ASSEMBLY

NOTICE:: ·

Keep the valve lash adjuster assembly free from dirt and foreign matter.

·

Only use clean engine oil.

a.

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

b.

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.

1.583,0.302 1.969,0.302 false 2.344,0.302 2.802,0.302 false 1.448,0.958 2.052,0.698 true 2.313,0.698 2.896,0.865 true 1.5,1.125 2.063,0.938 false 2.302,0.938 2.833,1.083 false 1.385,1.406 2.052,1.229 true 2.313,1.219 2.938,1.365 true 1.302,1.99 2.052,1.583 true 2.323,1.573 3.042,1.969 true 1.469,2.115 2.063,1.958 true 2.323,1.958 2.875,2.104 true 4.698,1.104 5.052,1.354 false 2.115,0.844 2.427,1.073 0.313,0.229 10 false *f 2.115,1.469 2.427,1.677 0.313,0.208 10 false *g 2.125,0.594 2.438,0.75 0.313,0.156 10 false *c 2.115,1.135 2.427,1.292 0.313,0.156 10 false *d 2.115,1.865 2.427,2.021 0.313,0.156 10 false *e 2.052,0.229 2.51,0.427 0.458,0.198 10 false SST 4.542,0.938 5,1.135 0.458,0.198 10 false SST 1.198,0.188 1.51,0.385 0.313,0.198 10 false *a 2.979,0.177 3.292,0.375 0.313,0.198 10 false *b

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

SST: 09276-75010

c.

Squeeze SST and the valve lash adjuster assembly together to move the plunger up and down 5 to 6 times.

d.

Check the movement of the plunger and bleed the air.

OK:: Plunger moves up and down.

NOTICE:: When bleeding the 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.

e.

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.

Hide Display 13506 3.INSPECT CHAIN SUB-ASSEMBLY

a.

1.688,0.969 2,1.167 0.313,0.198 10 false *a 0.979,2.021 1.271,2.177 0.292,0.156 10 false 0 1.385,2.021 1.677,2.177 0.292,0.156 10 false 1 2,2.021 2.292,2.177 0.292,0.156 10 false 14 2.406,2.021 2.698,2.177 0.292,0.156 10 false 15

*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.

b.

Using a vernier caliper, measure the length of 15 links.

Maximum Chain Elongation:: 121.6 mm (4.79 in.)

NOTICE:: 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.

Hide Display 13507 4.INSPECT NO. 2 CHAIN SUB-ASSEMBLY

a.

1.688,0.969 2,1.167 0.313,0.198 10 false *a 0.979,2.021 1.271,2.177 0.292,0.156 10 false 0 1.385,2.021 1.677,2.177 0.292,0.156 10 false 1 2,2.021 2.292,2.177 0.292,0.156 10 false 14 2.406,2.021 2.698,2.177 0.292,0.156 10 false 15

*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.

b.

Using a vernier caliper, measure the length of 15 links.

Maximum Chain Elongation:: 107.0 mm (4.21 in.)

NOTICE:: 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.

Hide Display 13540 5.INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY

a.

0.469,0.354 0.781,0.51 0.313,0.156 10 false *a 0.365,0.771 0.677,0.927 0.313,0.156 10 false *b 1.906,1.406 2.219,1.563 0.313,0.156 10 false *c

*a	Raise
*b	Move
*c	Lock

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

b.

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.

Hide Display 13050 6.INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

a.

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

b.

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

Minimum Gear Diameter (with Chain Sub-assembly):: 100.89 mm (3.97 in.)

NOTICE:: 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.

Hide Display 13070A 7.INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

a.

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

b.

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

Minimum Gear Diameter (with Chain Sub-assembly):: 100.89 mm (3.97 in.)

NOTICE:: 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 exhaust gear assembly.

Hide Display 13519 8.INSPECT OIL PUMP DRIVE GEAR

a.

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

b.

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):: 52.55 mm (2.07 in.)

NOTICE:: 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.

Hide Display 15163 9.INSPECT OIL PUMP DRIVE SHAFT GEAR

a.

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

b.

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):: 59.21 mm (2.33 in.)

NOTICE:: 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.

Hide Display 13521 10.INSPECT CRANKSHAFT TIMING SPROCKET

a.

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

b.

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

Minimum Gear Diameter (with Chain Sub-assembly):: 55.17 mm (2.17 in.)

NOTICE:: 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.

Hide Display 13559 11.INSPECT CHAIN TENSIONER SLIPPER

a.

3.01,0.76 3.323,0.917 0.313,0.156 10 false *a

*a

Depth

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

Maximum Depth:: 1.0 mm (0.0394 in.)

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

Hide Display 13566B 12.INSPECT TIMING CHAIN GUIDE

a.

2.896,1.01 3.208,1.167 0.313,0.156 10 false *a

*a

Depth

Using a vernier caliper, measure the wear depth of the timing chain guide.

Maximum Depth:: 1.0 mm (0.0394 in.)

HINT:: If the depth is more than the maximum, replace the timing chain guide.

Hide Display 13549 13.INSPECT CHAIN TENSIONER PLATE

a.

3.135,1.417 3.375,1.635 0.24,0.219 10 false *a

*a

Depth

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

Maximum Depth:: 0.5 mm (0.0197 in.)

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

Hide Display 11101A 14.INSPECT CYLINDER HEAD SET BOLT

a.

1.875,0.479 2.188,0.635 0.313,0.156 10 false *a 1.292,1.583 2.198,1.938 0.906,0.354 10 false *b

*a	Measurement Area
*b	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:: 10.85 to 11.00 mm (0.427 to 0.433 in.)

Minimum Diameter:: 10.6 mm (0.417 in.)

NOTICE:: ·

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.

Hide Display 13511 15.INSPECT CAMSHAFT

a.

Inspect the camshaft for runout.

i.

Place the camshaft on V-blocks.

ii.

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

Maximum Runout:: 0.04 mm (0.00157 in.)

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

b.

Inspect the cam lobes.

i.

Using a micrometer, measure the cam lobe height.

Standard Cam Lobe Height:: 41.699 to 41.799 mm (1.64169 to 1.64563 in.)

Minimum Cam Lobe Height:: 41.649 mm (1.63972 in.)

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

c.

Inspect the camshaft journals.

i.

Using a micrometer, measure the journal diameter.

Standard Journal Diameter:

Item	Specified Condition
No. 1 journal	34.449 to 34.465 mm (1.35626 to 1.35689 in.)
Other journals	22.954 to 22.970 mm (0.90370 to 0.90433 in.)

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

Hide Display 13512 16.INSPECT NO. 2 CAMSHAFT

a.

Inspect the No. 2 camshaft for runout.

i.

Place the No. 2 camshaft on V-blocks.

ii.

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

Maximum Runout:: 0.04 mm (0.00157 in.)

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

b.

Inspect the cam lobes.

i.

Using a micrometer, measure the cam lobe height.

Standard Cam Lobe Height:

Item	Specified Condition
except Fuel Pump Assembly	40.481 to 40.581 mm (1.59374 to 1.59767 in.)
for Fuel Pump Assembly	39.550 to 39.650 mm (1.55708 to 1.56102 in.)

Minimum Cam Lobe Height:

Item	Specified Condition
except Fuel Pump Assembly	40.331 mm (1.58783 in.)
for Fuel Pump Assembly	39.500 mm (1.55512 in.)

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

c.

Inspect the No. 2 camshaft journals.

i.

Using a micrometer, measure the journal diameter.

Standard Journal Diameter:

Item	Specified Condition
No. 1 journal	34.449 to 34.465 mm (1.35626 to 1.35689 in.)
Other journal	22.954 to 22.970 mm (0.90370 to 0.90433 in.)

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

Hide Display 17.INSPECT CAMSHAFT THRUST CLEARANCE

a.

Clean the camshaft, No. 2 camshaft and camshaft bearing caps.

b.

Place the camshaft and No. 2 camshaft on the camshaft housing sub-assembly.

c.

Install the camshaft housing sub-assembly.

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d.

Install the camshaft bearing caps.

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e.

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

Standard Thrust Clearance:: 0.06 to 0.20 mm (0.00236 to 0.00787 in.)

Maximum Thrust Clearance:: 0.25 mm (0.00984 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.

Hide Display 18.INSPECT CAMSHAFT OIL CLEARANCE

a.

Clean the camshaft bearing caps and camshaft journals.

b.

Place the camshaft and No. 2 camshaft on the camshaft housing sub-assembly.

c.

0.917,0.427 1.677,1.094 true 0.75,0.292 1.063,0.448 0.313,0.156 10 false *a

*a	Plastigage

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

d.

Install the camshaft bearing caps.

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NOTICE:: Do not turn the camshaft.

e.

Remove the camshaft bearing caps.

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f.

0.979,0.365 1.667,1.115 true 0.833,0.219 1.146,0.375 0.313,0.156 10 false *a

*a	Plastigage

Measure the Plastigage at its widest point.

Standard Oil Clearance:

Item	Specified Condition
No. 1 journal	0.035 to 0.072 mm (0.00138 to 0.00283 in.)
Other journals	0.030 to 0.067 mm (0.00118 to 0.00264 in.)

Maximum Oil Clearance:

Item	Specified Condition
No. 1 journal	0.08 mm (0.00315 in.)
Other journals	0.08 mm (0.00315 in.)

NOTICE:: Completely remove the Plastigage after the inspection.

HINT:: If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the cylinder head sub-assembly.

NR Series ENGINE MECHANICAL ENGINE UNIT INSPECTION

PROCEDURE