M20D-FKS ENGINE MECHANICAL  ENGINE UNIT  INSPECTION  

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.

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.

1.5,0.302 1.969,0.302 false 2.344,0.302 2.875,0.302 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 0.313,0.156 10 false *f 2.115,1.469 2.313,1.708 0.198,0.24 10 false *g 1.229,0.031 1.542,0.188 0.313,0.156 10 false *a 3.01,0.031 3.323,0.188 0.313,0.156 10 false *b 2.115,0.594 2.427,0.75 0.313,0.156 10 false *c 2.115,1.135 2.427,1.292 0.313,0.156 10 false *d 2.115,1.854 2.427,2.01 0.313,0.156 10 false *e 2.031,0.219 2.49,0.417 0.458,0.198 10 false SST 4.427,0.938 4.885,1.135 0.458,0.198 10 false SST

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

SST

09276-75010  

Inspect the intake camshaft sub-assembly for runout.

Inspect the cam lobes.

Inspect the intake camshaft sub-assembly journals.

Inspect the exhaust camshaft sub-assembly for runout.

Inspect the cam lobes.

Inspect the exhaust camshaft sub-assembly journals.

1.198,1.042 1.01,0.365 1.01,0.365 0.854,0.365 true 0.656,0.25 0.969,0.448 0.313,0.198 10 false *a

*a	Plastigage

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

0.604,0.813 0.802,0.813 0.802,0.813 1.167,1.333 true 0.542,3.885 0.281,3.146 0.281,3.146 0.552,3.24 true 2.625,3.396 1.896,4.51 1.896,4.51 1.083,3.365 true 2.156,3.396 1.896,4.49 1.896,4.49 1.604,3.375 true 2.635,3.979 1.896,4.5 1.896,4.5 1.094,3.969 true 2.156,3.969 1.896,4.49 1.896,4.49 1.625,3.979 true 0.406,0.708 0.719,0.906 0.313,0.198 10 false *a 0.094,3.031 0.406,3.229 0.313,0.198 10 false *b 1.823,4.5 2.135,4.667 0.313,0.167 10 false *c

*a	Plastigage
*b	No. 1 Journal
*c	Other Journal

Measure the Plastigage at its widest point.

Standard Oil Clearance (for intake camshaft sub-assembly):

Item	Specified Condition
No. 1 journal	0.035 to 0.072 mm (0.00138 to 0.00283 in.)
Other journals	0.025 to 0.062 mm (0.000984 to 0.00244 in.)

Standard Oil Clearance (for exhaust camshaft sub-assembly):

Item	Specified Condition
No. 1 journal	0.027 to 0.064 mm (0.00106 to 0.00252 in.)
Other journals	0.025 to 0.062 mm (0.000984 to 0.00244 in.)

Maximum Oil Clearance (for intake camshaft sub-assembly):

Item	Specified Condition
No. 1 journal	0.085 mm (0.00335 in.)
Other journals	0.085 mm (0.00335 in.)

Maximum Oil Clearance (for exhaust camshaft sub-assembly):

Item	Specified Condition
No. 1 journal	0.085 mm (0.00335 in.)
Other journals	0.085 mm (0.00335 in.)

NOTICE:

Completely remove the Plastigage after the inspection.

HINT:

If the oil clearance is more than the maximum, replace the intake camshaft sub-assembly or exhaust camshaft sub-assembly. If necessary, replace the camshaft housing sub-assembly.

1.625,0.906 1.938,1.104 0.313,0.198 10 false *a

*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.

1.625,0.906 1.938,1.104 0.313,0.198 10 false *a

*a	Measurement Length

Using a spring scale, pull the oil pump drive chain sub-assembly with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration.

Place the oil pump drive chain sub-assembly around the oil pump drive sprocket.

Place the oil pump drive chain sub-assembly around the oil pump drive shaft sprocket.

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

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

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

2.781,1.896 2.604,1.896 2.604,1.896 2.604,1.458 false 2.865,1.802 3.177,2 0.313,0.198 10 false *a

*a

Plunger

Push the plunger and check that it moves smoothly.

HINT:

If the plunger does not move smoothly, replace the No. 1 chain tensioner assembly.

3.177,1.063 3.427,1.26 0.25,0.198 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.

2.938,1.021 3.25,1.219 0.313,0.198 10 false *a

*a

Depth

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

Maximum Depth:

1.0 mm (0.0394 in.)

HINT:

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

Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth.

Standard Thrust Clearance:

0.05 to 0.09 mm (0.00197 to 0.00354 in.)

Maximum Thrust Clearance:

0.09 mm (0.00354 in.)

HINT:

If the thrust clearance is more than the maximum, replace the engine balancer assembly.

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

Standard Thrust Clearance:

0.05 to 0.09 mm (0.00197 to 0.00354 in.)

Maximum Thrust Clearance:

0.09 mm (0.00354 in.)

HINT:

If the thrust clearance is more than the maximum, replace the engine balancer assembly.

1.375,0.323 1.615,0.521 0.24,0.198 10 false *a

*a

Secure

Secure the No. 3 balance shaft in place, and then using a dial indicator, measure the backlash of the No. 2 balance shaft and No. 3 balance shaft as shown in the illustration.

Standard Backlash:

0.045 to 0.155 mm (0.00177 to 0.00610 in.)

Maximum Backlash:

0.155 mm (0.00610 in.)

NOTICE:

Measure at 3 or more areas around the circumference of the No. 2 balance shaft and No. 3 balance shaft.

HINT:

If the backlash is more than the maximum, replace the engine balancer assembly.

for 140 mm cylinder head set bolt:

i.

2.219,0.344 2.531,0.542 0.313,0.198 10 false *a 1.292,1.51 1.604,1.708 0.313,0.198 10 false *b

*a	Measurement Point
*b	10.5 mm (0.413 in.)

Using a vernier caliper, measure the diameter of the threads at the measurement point.

Standard Diameter:

10.7 to 10.9 mm (0.421 to 0.429 in.)

Minimum Diameter:

10.6 mm (0.417 in.)

Measurement Point (Distance from the Seat):

10.5 mm (0.413 in.)

HINT:

·

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.

for 130 mm cylinder head set bolt:

i.

2.219,0.344 2.531,0.542 0.313,0.198 10 false *a 1.292,1.51 1.604,1.708 0.313,0.198 10 false *b

*a	Measurement Point
*b	11.5 mm (0.453 in.)

Using a vernier caliper, measure the diameter of the threads at the measurement point.

Standard Diameter:

9.7 to 9.9 mm (0.382 to 0.390 in.)

Minimum Diameter:

9.6 mm (0.378 in.)

Measurement Point (Distance from the Seat):

9.5 mm (0.374 in.)

HINT:

·

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.

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

Maximum Warpage:

0.7 mm (0.0276 in.)

HINT:

If the warpage is more than the maximum, replace the exhaust manifold (TWC: Front Catalyst).

1.26,1.854 1.521,1.479 1.521,1.479 1.625,1.479 false 0.479,1.677 0.344,1.042 0.344,1.042 0.271,1.042 true 2.906,0.823 3.219,1.021 0.313,0.198 10 false *a 2.083,1.042 2.396,1.24 0.313,0.198 10 false *b 2.396,0.75 2.854,0.948 0.458,0.198 10 false 90° 1.896,0.167 2.208,0.365 0.313,0.198 10 false *d 1.656,1.385 1.969,1.583 0.313,0.198 10 false *d 0.083,0.927 0.396,1.125 0.313,0.198 10 false *c

*a	1 mm (0.0394 in.)
*b	5 mm (0.197 in.)
*c	Check Valve
*d	Wire
	Move the wire in this direction.
	Movement of Check Valve

Using a piece of wire, check that the check valve is not stuck.

HINT:

·

Form a 1 mm (0.0394 in.) diameter piece of wire to the shape shown in the illustration.

·

If the check valve is stuck, replace the oil nozzle valve sub-assembly with a new one.

1.354,1.635 0.854,1.406 0.854,1.406 1.396,1.49 true 1.854,1.781 2.615,1.688 2.615,1.688 1.896,1.635 true 0.969,0.49 1.115,0.49 1.115,0.49 1.563,0.688 false 1.854,0.323 2.01,0.521 0.156,0.198 10 false A 0.688,1.302 0.844,1.5 0.156,0.198 10 false B 2.677,1.594 2.833,1.792 0.156,0.198 10 false B 0.792,0.406 1.104,0.604 0.313,0.198 10 false *a

*a

Hose

Connect a hose to the oil nozzle valve sub-assembly.

1.281,1.448 0.906,1.333 0.906,1.333 1.313,1.323 true 1.75,1.552 2.344,1.719 2.344,1.719 1.781,1.438 true 1.292,0.323 1.563,0.323 false 2.073,0.313 2.229,0.51 0.156,0.198 10 false A 0.771,1.26 0.927,1.458 0.156,0.198 10 false B 2.417,1.667 2.573,1.865 0.156,0.198 10 false B 1.115,0.229 1.427,0.427 0.313,0.198 10 false *a

*a	Hose
	Move the wire in this direction.
	Movement of Check Valve

With the check valve depressed using a piece of wire, check that air flows from the port (B) when blowing air into the port (A).

HINT:

If air does not flow from the port (B), replace the oil nozzle valve sub-assembly with a new one.