Inspection

CAMSHAFT

Inspection


EXHAUST CAMSHAFT VALVE CLEARANCE ADJUSTMENT

- Perform adjustment depending on selected head thickness of valve lifter (EXH).
1.Measure the valve clearance. Service and Repair.
2.Remove VVEL ladder assembly and exhaust camshaft. Removal And Installation.

CAUTION:
Never loosen adjusting bolts and mounting bolts (black color) of VVEL ladder assembly.
3.Remove valve lifter (EXH) at the locations that are out of the standard.





4.Measure the center thickness of the removed valve lifters (EXH)
with a micrometer (A).
5.Use the equation below to calculate valve lifter (EXH) thickness for replacement.









- Thickness of new valve lifter (EXH) can be identified by stamp marks on the reverse side (inside the cylinder).
Stamp mark 788 indicates 7.88 mm (0.3102 in) in thickness.





Available thickness of valve lifter (EXH): 27 sizes with range 7.88 to 8.40 mm (0.3102 to 0.3307 in) in steps of 0.02 mm (0.0008 in) (when manufactured at factory). [1][2]Camshaft, Engine.
6.Install selected valve lifter (EXH).
7.Install VVEL ladder assembly and exhaust camshaft. Removal And Installation.
8.Manually turn crankshaft pulley a few turns.
9.Check that the valve clearances for cold engine are within the specifications by referring to the specified values. Service and Repair.
10.Install all removed parts in the reverse order of removal.
11.Warm up the engine, and check for unusual noise and vibration.

INSPECTION AFTER DISASSEMBLY (EXHAUST SIDE)

Exhaust Camshaft Runout





1.Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.

CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations.
2.Set a dial indicator vertically to No. 3 journal.
3.Turn exhaust camshaft to one direction with hands, and measure the camshaft runout on a dial indicator. (Total indicator reading)
Standard and limit: [1][2]Camshaft, Engine.
4.If it exceeds the limit, replace exhaust camshaft.
Exhaust Camshaft Cam Height





- Measure the exhaust camshaft cam height with a micrometer.
Standard and limit: [1][2]Camshaft, Engine.
- If wear exceeds the limit, replace exhaust camshaft.
Exhaust Camshaft Journal Oil Clearance





- Measure the outer diameter of exhaust camshaft journal with a micrometer (A).
Standard: [1][2]Camshaft, Engine.
- Tighten VVEL ladder assembly bolts to the specified torque. Refer to "ASSEMBLY" for the tightening procedure.





- Measure inner diameter (A) of VVEL ladder assembly (exhaust side) with a bore gauge.
Standard: [1][2]Camshaft, Engine.
- (Oil clearance) = [VVEL ladder assembly (exhaust side) inner diameter] - [Exhaust camshaft journal diameter].
Standard and limit: [1][2]Camshaft, Engine.
- If the calculated value exceeds the limit, replace either or both exhaust camshaft and VVEL ladder assembly
& cylinder head assembly.
NOTE:
VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder head assembly.
Exhaust Camshaft End Play





- Install a dial indicator in thrust direction on front end of camshaft.
Measure the end play of a dial indicator when exhaust camshaft is moved forward/backward (in direction of axis).
Standard and limit: [1][2]Camshaft, Engine.





- Measure the following parts if out of the limit.
- Dimension "A" for exhaust camshaft No. 1 journal





- Dimension "B" for cylinder head No. 1 journal bearing





- Refer to the standards above, and then replace exhaust camshaft and/or VVEL ladder assembly & cylinder head assembly.
NOTE:
Cylinder head assembly cannot be replaced as a single part, because it is machined together with VVEL ladder assembly.
Exhaust Camshaft Sprocket Runout
1.Put V-block on precise flat table, and support No. 2 and 5 journals of exhaust camshaft.

CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations.





2.Measure the exhaust camshaft sprocket runout with a dial indicator. (Total indicator reading)
Limit: [1][2]Camshaft, Engine.
3.If it exceeds the limit, replace exhaust camshaft sprocket.
Valve Lifter (EXH)





- Check if surface of valve lifter has any wear or crack.
- If wear or crack is found, replace valve lifter (EXH). [1][2]Camshaft, Engine.
Valve Lifter Clearance (EXH)





- Measure the outer diameter at 1/2 height of valve lifter with a micrometer (A) since valve lifter is in barrel shape.
Standard: [1][2]Camshaft, Engine.





- Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer.
Standard: [1][2]Camshaft, Engine.
- (Valve lifter clearance) = (Valve lifter hole diameter) - (Valve lifter outer diameter)
Standard: [1][2]Camshaft, Engine.
- If the calculated value is out of the standard, referring to each standard of valve lifter outer diameter and valve lifter hole diameter, replace either or both valve lifter and VVEL ladder assembly & cylinder head assembly.
NOTE:
Cylinder head assembly cannot be replaced as a single part, because it is machined together with VVEL ladder assembly.

INSPECTION AFTER DISASSEMBLY (INTAKE SIDE)

Drive Shaft End Play





- Install a dial indicator in thrust direction on front end of drive shaft.
Measure the end play of a dial indicator when drive shaft is moved forward/backward (in direction of axis).





Standard and limit: [1][2]Camshaft, Engine.





- Measure the following parts if out of the limit.





- Dimension "A" for drive shaft No. 1 journal





- Dimension "B" for cylinder head No. 1 journal bearing





- If it exceeds the limit, replace VVEL ladder assembly & cylinder head assembly.
NOTE:
Cylinder head assembly cannot be replaced as a single part, because it is machined together with VVEL ladder assembly.
Camshaft Sprocket (INT) Runout
1.Put V-block on precise flat table, and support No. 2 and 5 journals of drive shaft.

CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations.
2.Measure the camshaft sprocket (INT) runout with a dial indicator. (Total indicator reading)
Limit: [1][2]Camshaft, Engine.
3.If it exceeds the limit, replace camshaft sprocket (INT).
Valve Lifter (INT)





- Check if surface of valve lifter has any wear or crack.
- If wear or crack is found, replace VVEL ladder assembly & cylinder head assembly. [1][2]Camshaft, Engine.
NOTE:
Since the valve lifter (INT) cannot be replaced by the piece, VVEL
ladder assembly & cylinder head assembly replacement are required.
Valve Lifter Clearance (INT)





- Measure the outer diameter at 1/2 height of valve lifter (INT) with a micrometer (A) since valve lifter is in barrel shape.
Standard: [1][2]Camshaft, Engine.





- Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer.
Standard: [1][2]Camshaft, Engine.
- (Valve lifter clearance) = (Valve lifter hole diameter) - (Valve lifter outer diameter)
Standard: [1][2]Camshaft, Engine.
- If the calculated value is out of the standard, replace VVEL ladder assembly & cylinder head assembly.
NOTE:
Since the valve lifter (INT) cannot be replaced by the piece, VVEL ladder assembly & cylinder head assembly replacement are required.
VVEL Ladder Assembly





- Hold the both ends of the drive shaft (A) and rotate it to check that it rotates smoothly.

CAUTION:
Turn VVEL ladder assembly upside down to prevent the drive shaft from dropping off.





- Move control shaft (A) to the small stopper and large stopper to check that the control shaft functions smoothly.

CAUTION:
Turn VVEL ladder assembly upside down to prevent the drive shaft from dropping off.










- Check that the link and the shaft of drive shaft and control shaft are not fixed.
- Check this by moving drive shaft and control shaft in the axial and rotation directions.
- If there is an unusualness related to the above three items, replace VVEL ladder assembly & cylinder head assembly.
NOTE:
VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder head assembly.

INSPECTION AFTER ASSEMBLY

Inspection of Camshaft Sprocket (INT) Oil Groove

CAUTION:
- Perform this inspection only when DTC P0011, P0021 are detected in self-diagnostic results of CONSULT and it is directed according to inspection procedure of EC section. Refer to the following table:





- Check when engine is cold to prevent burns from the splashing engine oil.
1.Check engine oil level. Inspection.
2.Perform the following procedure to prevent the engine from being unintentionally started while checking.
a.Release the fuel pressure. Refer to the following table:





b.Disconnect ignition coil and injector harness connectors.
3.Release fuel pressure. Refer to the following table:
4.Remove valve timing control solenoid valve. Exploded View.





5.Crank engine, and then check that engine oil comes out from valve timing control solenoid valve hole (A). End crank after checking.






WARNING:
Be careful not to touch rotating parts (drive belt, idler pulley, and crankshaft pulley, etc.).

CAUTION:
- Prevent splashing by using a shop cloth to prevent the worker from injury from engine oil and to prevent engine oil contamination.
- Prevent splashing by using a shop cloth to prevent engine oil from being splashed to engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belt, engine mounting insulator, etc. Wipe engine oil out immediately if it is splashed.
6.Perform the following inspection if engine oil does not come out from valve timing control solenoid valve oil hole of the valve timing control cover.
- Remove oil filter, and then clean it. Exploded View.
- Clean oil groove between oil strainer and valve timing control solenoid valve. Engine Lubrication System and Engine Lubrication System Schematic.
7.Remove components between valve timing control solenoid valve and camshaft sprocket, and then check each oil groove for clogging.
- Clean oil groove if necessary. Engine Lubrication System and Engine Lubrication System Schematic.
8.After inspection, install removed parts in the reverse order.
Inspection for Leakage
- Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the required quantity, fill them to the specified level.
- Follow the procedure below to check for fuel leakage.
- Turn ignition switch to the "ON" position (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
- Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after the engine start. However, this does not indicate a malfunction. The noise will stop after hydraulic pressure rises.
- Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant.
- Bleed air from lines and hoses of applicable lines, such as in cooling system.
- After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to the specified level, if necessary.
Summary of the inspection items: