Part 1

INSPECTION

1. INSPECT BALANCE SHAFT THRUST CLEARANCE
(a) Install the balance shafts.
(b) Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
Standard thrust clearance: 0.05 to 0.09 mm (0.0020 to 0.0035 inch)
Maximum thrust clearance: 0.09 mm (0.0035 inch)
If the thrust clearance is greater than the maximum, replace the balance shaft housing and bearings. If necessary, replace the balance shaft.
2. INSPECT BALANCE SHAFT OIL CLEARANCE
(a) Clean each bearing and journal.
(b) Check each bearing and journal for pitting and scratches.
If a bearing or journal is damaged, replace the bearings. If necessary, replace the balance shaft.
(c) Place the No. 1 and No. 2 balance shafts onto the crankcase.
(d) Lay a strip of Plastigage across each journal.

(e) Install the balance shaft housing.

NOTICE: Do not turn the balance shafts.

(f) Remove the balance shafts.

(g) Measure the Plastigage at its widest point.
Standard oil clearance: 0.004 to 0.049 mm (0.0002 to 0.0019 inch)
Maximum oil clearance: 0.049 mm (0.0019 inch)

NOTICE:
- Remove the Plastigage completely after the measurement.
- If the oil clearance is greater than the maximum, replace the bearing. If necessary, replace the balance shaft.

(h) If replacing a bearing, select a new one with the same number.

Standard Balance Shaft Housing Journal Bore Diameter:

Standard Bearing Center Wall Thickness:

Standard Balance Shaft Journal Diameter:

(i) Inspect the balance shaft housing bolts.
(1) Using vernier calipers, measure the length of the bolts from the seat to the end.
Standard bolt length: 58.3 to 59.7 mm (2.295 to 2.350 inch)
Maximum bolt length: 60.3 mm (2.374 inch)
If the bolt length is greater than the maximum, replace the balance shaft housing bolt.

3. INSPECT CHAIN SUB-ASSEMBLY
(a) Pull the chain with a force of 140 N (14.3 kgf, 31.5 lbs.) as shown in the illustration.
(b) Using vernier calipers, measure the length of 15 links.
Maximum chain elongation: 114.5 mm (4.508 inch)

NOTICE: Perform the measurement at 3 random places. Use the average of the measurements.

If the elongation is greater than the maximum, replace the chain.

4. INSPECT NO. 2 CHAIN SUB-ASSEMBLY
(a) Pull the chain with a force of 140 N (14.3 kgf, 31.5 lbs.) as shown in the illustration.
(b) Using vernier calipers, measure the length of 15 links.
Maximum chain elongation: 102.2 mm (4.024 inch)

NOTICE: Perform the measurement at 3 random places. Use the average of the measurements.

If the elongation is greater than the maximum, replace the No. 2 chain.

5. INSPECT OIL PUMP DRIVE GEAR
(a) Wrap the chain around the sprocket.
(b) Using vernier calipers, measure the sprocket diameter with the chain wrapped around.
Minimum gear diameter (with chain): 48.2 mm (1.898 inch)

NOTICE: The vernier calipers must be in contact with the chain rollers when measuring.

If the diameter is less than the minimum, replace the chain and sprocket.

6. INSPECT OIL PUMP DRIVE SHAFT GEAR
(a) Wrap the chain around the sprocket.
(b) Using vernier calipers, measure the sprocket diameter with the chain wrapped around.
Minimum gear diameter (with chain): 48.2 mm (1.898 inch)

NOTICE: The vernier calipers must be in contact with the chain rollers when measuring.

If the diameter is less than the minimum, replace the chain and sprocket.

7. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Wrap the chain around the sprocket.
(b) Using vernier calipers, measure the sprocket diameter with the chain wrapped around.
Minimum gear diameter (with chain): 97.3 mm (3.831 inch)

NOTICE: The vernier calipers must be in contact with the chain rollers when measuring.

If the diameter is less than the minimum, replace the chain and sprocket.

8. INSPECT CAMSHAFT TIMING SPROCKET
(a) Wrap the chain around the sprocket.
(b) Using vernier calipers, measure the sprocket diameter with the chain wrapped around.
Minimum gear diameter (with chain): 97.3 mm (3.831 inch)

NOTICE: The vernier calipers must be in contact with the chain rollers when measuring.

If the diameter is less than the minimum, replace the chain and sprocket.

9. INSPECT CRANKSHAFT TIMING GEAR
(a) Wrap the chain around the timing sprocket.
(b) Using vernier calipers, measure the timing gear diameter with the chain wrapped around.
Minimum gear diameter (with chain): 51.6 mm (2.031 inch)

NOTICE: The vernier calipers must be in contact with the chain rollers when measuring.

If the gear diameter is less than the minimum, replace the chain sub-assembly and crankshaft timing sprocket.

10. INSPECT CHAIN TENSIONER SLIPPER
(a) Using vernier calipers, measure the tensioner slipper wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than the maximum, replace the chain tensioner slipper.

11. INSPECT NO. 1 CHAIN VIBRATION DAMPER
(a) Using vernier calipers, measure the vibration damper wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than the maximum, replace the No. 1 chain vibration damper.

12. INSPECT CHAIN TENSIONER PLATE
(a) Using vernier calipers, measure the vibration damper wear.
Maximum wear: 0.5 mm (0.020 inch)
If the wear is greater than the maximum, replace the chain tensioner plate.

13. INSPECT NO. 1 CHAIN TENSIONER
(a) Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.
(b) Release the ratchet pawl, then check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
14. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Install the connecting rod cap.

(b) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.160 to 0.362 mm (0.0063 to 0.0143 inch)
Maximum thrust clearance: 0.362 mm (0.0143 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assemblies as necessary. If necessary, replace the crankshaft.
15. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Clean the crank pin and bearing.
(b) Check the crank pin and bearing for pitting and scratches.

(d) Check that the front mark of the connecting rod cap is facing forward.
(e) Install the connecting rod cap.

NOTICE: Do not turn the crankshaft.

(f) Remove the 2 bolts and connecting rod cap.

(g) Measure the Plastigage at its widest point.
Standard oil clearance: 0.032 to 0.063 mm (0.0013 to 0.0025 inch)
Maximum oil clearance: 0.063 mm (0.0025 inch)

NOTICE: Completely remove the Plastigage after the measurement.

If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, inspect the crankshaft.

HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2, or 3 mark on its surface.

Standard Connecting Rod Large End Bore Diameter:

Standard Connecting Rod Bearing Thickness:

Standard Crankshaft Pin Diameter:

16. INSPECT CYLINDER BLOCK FOR WARPAGE
(a) Using a precision straightedge and feeler gauge, measure the warpage of the surface that is in contact with the cylinder head gasket.
Maximum warpage: 0.05 mm (0.0020 inch)
If the warpage is greater than the maximum, replace the cylinder block.