INSPECT CAMSHAFT

INSPECT CAMSHAFT OIL CLEARANCE

INSPECT NO. 2 AND NO. 3 CAMSHAFT THRUST CLEARANCE (for Intake Camshaft)

INSPECT NO. 1 AND NO. 4 CAMSHAFT THRUST CLEARANCE (for Exhaust Camshaft)

INSPECT VALVE ROCKER ARM SUB-ASSEMBLY

INSPECT VALVE LASH ADJUSTER ASSEMBLY

INSPECT INNER COMPRESSION SPRING

CLEAN VALVE

INSPECT VALVE

INSPECT VALVE GUIDE BUSH OIL CLEARANCE

CLEAN CYLINDER HEAD SUB-ASSEMBLY

INSPECT CYLINDER HEAD SUB-ASSEMBLY

CLEAN VALVE SEAT

INSPECT INTAKE VALVE SEAT

INSPECT EXHAUST VALVE SEAT

Inspect the camshaft for runout.

Inspect the cam lobe height.

Inspect the camshaft journal diameter.

Clean the camshaft bearing caps and camshaft journals.

Place the camshafts on the cylinder head.

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

Temporarily install the camshaft bearing cap with the 4 bolts by hand.

• NOTICE:

• Do not turn the camshafts.

Install the No. 3 camshaft bearing caps with the 16 bolts.

Confirm the marks and numbers on the camshaft bearing caps and place them in their proper position and direction.

Temporarily install the 16 bolts.

Uniformly tighten the 20 bolts in several steps in the order shown in the illustration.

• Torque:
• for 12 mm head bolt of No. 1 and No. 4 camshaft bearing cap:
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}
• for 10 mm head bolt of No. 3 camshaft bearing cap:
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.

Measure the Plastigage at its widest point.

• Standard oil clearance:
• 0.025 to 0.062 mm (0.000984 to 0.00244 in.)

• Maximum oil clearance:
• 0.072 mm (0.00283 in.)

If the oil clearance is more than the maximum, replace the camshaft.

If necessary, replace the cylinder head sub-assembly.

Remove the Plastigage completely.

Remove the camshafts.

Install the No. 2 and No. 5 camshaft bearing caps to the cylinder head.

Place the camshafts on the cylinder head.

Temporarily install the No. 1 and No. 4 camshaft bearing caps with the 4 bolts by hand.

• NOTICE:

• Do not turn the camshafts.

Install the No. 3 camshaft bearing caps.

Confirm the marks and numbers on the camshaft bearing caps and place them in their proper position and direction.

Temporarily install the 16 bolts.

Uniformly tighten the 24 bolts in several steps in the order shown in the illustration.

• Torque:
• for 12 mm head bolt of No. 1 and No. 4 camshaft bearing cap:
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}
• for 10 mm head bolt of No. 3 camshaft bearing cap:
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

• Standard thrust clearance:
• 0.035 to 0.160 mm (0.00138 to 0.00630 in.)

• Maximum thrust clearance:
• 0.180 mm (0.00709 in.)

If the thrust clearance is more than the maximum, replace the camshaft.

If necessary, replace the cylinder head sub-assembly.

Install the No. 2 and No. 5 camshaft bearing caps to the cylinder head.

Place the camshafts on the cylinder head.

Temporarily install the No. 1 and No. 4 camshaft bearing caps with the 4 bolts by hand.

• NOTICE:

• Do not turn the camshafts.

Install the No. 3 camshaft bearing caps.

Confirm the marks and numbers on the camshaft bearing caps and place them in their proper position and direction.

Temporarily install the 16 bolts.

Uniformly tighten the 24 bolts in several steps in the order shown in the illustration.

• Torque:
• for 12 mm head bolt of No. 1 and No. 4 camshaft bearing cap:
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}
• for 10 mm head bolt of No. 3 camshaft bearing cap:
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

• Standard thrust clearance:
• 0.035 to 0.160 mm (0.00138 to 0.00630 in.)

• Maximum thrust clearance:
• 0.180 mm (0.00709 in.)

If the thrust clearance is more than the maximum, replace the camshafts.

If necessary, replace the cylinder head sub-assembly.

Turn the roller by hand to check that it turns smoothly.

If the roller does not turn smoothly, replace the valve rocker arm.

Place the lash adjuster into a container full of new engine oil.

Insert SST tip into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

• SST
• 09276-75010

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

Check the movement of the plunger and bleed air.

• OK:
• Plunger moves up and down.

• NOTICE:

• When bleeding high-pressure air from the compression 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.

After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers.

• OK:
• Plunger can be pressed 3 times.

If the plunger can still be compressed after pressing it 3 times, replace the lash adjuster with a new one.

Inspect the inner compression spring deviation.

Using a steel square, measure the deviation of the inner compression spring.

• Maximum deviation:
• 1.5 mm (0.0591 in.)

If the deviation is more than the maximum, replace the inner compression spring.

Inspect the inner compression spring free length.

Using a vernier caliper, measure the free length of the inner compression spring.

• Standard free length:
• 45.9 mm (1.81 in.)

If the free length is not as specified, replace the inner compression spring.

Inspect the inner compression spring tension.

Using a spring tester, measure the tension of the inner compression spring at the specified installed length.

• Installed tension:
• 219 to 242 N (22 to 25 kgf, 49.2 to 54.4 lbf) at 31.0 mm (1.22 in.)

If the installed tension is not as specified, replace the inner compression spring.

Using a gasket scraper, chip off any carbon from the valve head.

• NOTICE:

• Be careful not to damage the valve face.

Using a wire brush, thoroughly clean the valve.

Inspect the valve stem diameter.

Inspect the valve face angle.

Inspect the valve head margin thickness.

Inspect the valve overall length.

Inspect the valve stem tip.

Using a caliper gauge, measure the inside diameter of the guide bush.

• Standard bush inside diameter:
• 6.01 to 6.03 mm (0.2366 to 0.2374 in.)

Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.

• Standard Oil Clearance:

• Item	Specified Condition
  Intake	0.025 to 0.060 mm (0.000984 to 0.00236 in.)
  Exhaust	0.035 to 0.070 mm (0.00138 to 0.00276 in.)

• Maximum Oil Clearance:

• Item	Specified Condition
  Intake	0.120 mm (0.00472 in.)
  Exhaust	0.130 mm (0.00512 in.)

If the oil clearance is more than the maximum, replace the valve guide bush.

Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.

• NOTICE:

• Be careful not to scratch the cylinder block contact surface.

Using a wire brush, remove all the carbon from the combustion chambers.

• NOTICE:

• Be careful not to damage the combustion chambers and valve seats.

Using a valve guide bushing brush and solvent, clean all the valve guide bushes.

Using a soft brush and solvent, thoroughly clean the cylinder head.

Using a precision straightedge and feeler gauge, measure the warpage of the contact surface between the cylinder head and cylinder block, and the cylinder head and manifolds.

• Standard Warpage:

• Item	Specified Condition
  Cylinder block side	0 to 0.05 mm (0 to 0.00197 in.)
  Intake manifold side	0 to 0.08 mm (0 to 0.00315 in.)
  Exhaust manifold side	0 to 0.08 mm (0 to 0.00315 in.)

• Maximum Warpage:

• Item	Specified Condition
  Cylinder block side	0.05 mm (0.00197 in.)
  Intake manifold side	0.08 mm (0.00315 in.)
  Exhaust manifold side	0.08 mm (0.00315 in.)

If the warpage is more than the maximum, replace the cylinder head sub-assembly.

Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks.

If there are cracks, replace the cylinder head sub-assembly.

Using a 45° carbide cutter, resurface the valve seats.

• NOTICE:

• Be careful not to damage the combustion chambers and valve seats.

Clean the valve seats.

Apply a light coat of Prussian blue to the valve face.

Lightly press the valve face against the valve seat.

• NOTICE:

• Do not rotate the valve while pressing the valve.

Check the valve face and valve seat.

Apply a light coat of Prussian blue to the valve face.

Lightly press the valve face against the valve seat.

• NOTICE:

• Do not rotate the valve while pressing the valve.

Check the valve face and valve seat.