Inspection
INSPECTION1. CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK
a. Turn the crankshaft, and bring each piston to Top Dead Center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface.
b. Using a gasket scraper, remove all the gasket material from the cylinder block surface.
c. Using compressed air, blow carbon and oil from the bolt holes.
CAUTION: Protect your eyes when using high pressure compressed air.
2. REMOVE GASKET MATERIAL
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.
3. CLEAN COMBUSTION CHAMBERS
Using a wire brush, remove all the carbon from the combustion chambers.
NOTICE: Be careful not to scratch the cylinder block contact surface.
4. CLEAN CYLINDER HEADS
Using a soft brush and solvent, thoroughly clean the cylinder head.
5. CLEAN VALVE GUIDE BUSHINGS
Using a valve guide bushing brush and solvent, clean all the guide bushings.
6. INSPECT FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage.
Maximum warpage: 0.10 mm (0.0039 inch)
If warpage is greater than maximum, replace the cylinder head.
7. INSPECT FOR CRACKS
Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.
8. CLEAN VALVES
a. Using a gasket scraper, chip off any carbon from the valve head.
b. Using a wire brush, thoroughly clean the valve.
9. INSPECT VALVE STEMS AND GUIDE BUSHINGS
a. Using a caliper gauge, measure the inside diameter of the guide bushing.
Bushing inside diameter: 5.510 - 5.530 mm (0.2169 - 0.2177 inch)
b. Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter:
c. Subtract the valve stem diameter measurement from the guide bushing guide bushing inside diameter measurement.
Standard oil clearance:
Maximum oil clearance:
If the clearance is greater than maximum, replace the valve and guide bushing.
10. INSPECT AND GRIND VALVES
a. Grind the valve enough to remove pits and carbon.
b. Check that the valve is ground to the correct valve face angle.
Valve face angle: 44.5°
c. Check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 inch)
Minimum margin thickness: 0.5 mm (0.020 inch)
If the margin thickness is less than minimum, replace the valve.
d. Check the valve overall length.
Standard overall length:
Minimum overall length:
If the overall length is less than minimum, replace the valve.
e. Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.
NOTICE: Do not grind off more than minimum.
11. INSPECT AND CLEAN VALVE SEATS
a. Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.
b. Check the valve seating position. Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve.
c. Check the valve face and seat for the following:
- If blue appears 360° around the face, the valve is concentric. If not, replace the valve.
- If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat.
- Check that the seat contact is in the middle of the valve face with the following width: 1.0 - 1.4 mm (0.039 - 0.055 inch)
If not, correct the valve seats as follows:
1. If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.
2. If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat.
d. Hand-lap the valve and valve seat with an abrasive compound.
e. After hand-lapping, clean the valve and valve seat.
12. INSPECT VALVE SPRINGS
a. Using a steel square, measure the deviation of the valve spring.
Maximum deviation: 2.0 mm (0.079 inch)
If the deviation is greater than maximum, replace the valve spring.
b. Using vernier calipers, measure the free length of the valve spring.
Free length: 45.50 mm (1.7913 inch)
If the free length is not as specified, replace the valve spring.
c. Using a spring tester, measure the tension of the valve spring at the specified installed length.
Installed tension: 186 - 206 N (19.0 - 21.0 kgf, 41.9 - 46.3 lbs.) at 33.8 mm (1.331 inch)
If the installed tension is not as specified, replace the valve spring.
13. INSPECT CAMSHAFT FOR RUNOUT
a. Place the camshaft on V-blocks.
b. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.06 mm (0.0024 inch)
If the circle runout is greater than maximum, replace the camshaft.
14. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Minimum cam lobe height:
If the cam lobe height is less than minimum, replace the camshaft.
15. INSPECT CAMSHAFT JOURNALS
Using a micrometer, measure the journal diameter.
Journal diameter: 26.959 - 26.975 mm (1.0613 - 1.0620 inch)
If the journal diameter is not as specified, check the oil clearance.
16. INSPECT CAMSHAFT BEARINGS
Check that bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set.
17. INSPECT CAMSHAFT JOURNAL OIL CLEARANCE
a. Clean the bearing caps and camshaft journals.
b. Place the camshafts on the cylinder head.
c. Lay a strip of Plastigage across each of the camshaft journal.
d. Install the bearing caps.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
NOTICE: Do not turn the camshaft.
e. Remove the bearing caps.
f. Measure the Plastigage at its widest point.
Standard oil clearance:
Maximum oil clearance:
If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
g. Completely remove the Plastigage.
h. Remove the camshafts.
18. INSPECT CAMSHAFT THRUST CLEARANCE
a. Install the camshafts.
b. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance: 0.040 - 0.090 mm (0.0016 - 0.0035 inch)
Maximum thrust clearance: 0.12 mm (0.0047 inch)
If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
c. Remove the camshafts.
19. INSPECT CAMSHAFT GEAR BACKLASH
a. Install the camshafts without installing the exhaust cam sub-gear.
b. Using a dial indicator, measure the backlash.
Standard backlash: 0.020 - 0.200 mm (0.0008 - 0.0079 inch)
Maximum backlash: 0.30 mm (0.0188 inch)
If the backlash is greater then maximum, replace the camshafts.
c. Remove the camshafts.
20. INSPECT CAMSHAFT TIMING GEAR (VVT-i)
a. Mount the hexagon wrench head portion of the camshaft in a vise.
b. Check that VVT-i will not turn.
c. Cover the port except the port on the advance angle side (nearest to the convex portion) shown in the illustration with the vinyl tape.
d. Using the air gun, apply about 100 kPa (1 kgf/cm3, 14 psi) of air pressure to the port on the advance side shown in the illustration.
NOTICE: When the oil is splashed, wipe it off with a shop lug and the likes.
HINT: Perform this in order to release the lock pin for the maximum delay angle locking.
Standard: Must turn
HINT: Depending on the air pressure, VVT-i will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released.
e. Under the condition of (d), turn VVT-i to the advance angle side (the white arrow marked direction in the illustration) with your hand.
f. Except the position where the lock pin meets at the maximum delay angle, let VVE-i turn back and forth and check the movable range and that there is no disturbance.
Standard: Movable smoothly in the range about 30°
g. Turn VVT-i with your hand and lock it at the maximum delay angle position.
21. INSPECT CAMSHAFT GEAR SPRING
Using vernier calipers, measure the free distance between the spring ends.
Free distance: 18.2 - 18.8 mm (0.712 - 0.740 inch)
If the free distance is not as specified, replace the gear spring.
22. INSPECT VALVE LIFTERS AND LIFTER BORES
a. Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
Lifter bore diameter: 31.000 - 31.018 mm (1.2205 - 1.2212 inch)
b. Using a micrometer, measure the lifter diameter.
Lifter diameter: 30.966 - 30.976 mm (1.2191 - 1.2195 inch)
c. Subtract the lifter diameter measurement from the lifter bore diameter measurement.
Standard oil clearance: 0.024 - 0.050 mm (0.0009 - 0.0020 inch)
Maximum oil clearance: 0.07 mm (0.0028 inch)
If the oil clearance is greater than maximum, replace the lifter.
If necessary, replace the cylinder head.
23. INSPECT AIR INTAKE CHAMBER
Using a precision straight edge and feeler gauge, measure the surface contacting the intake manifold for warpage.
Maximum warpage: 0.10 mm (0.0039 inch)
If warpage is greater than maximum, replace the chamber.
24. INSPECT INTAKE MANIFOLD
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head and air intake chamber for warpage.
Maximum warpage:
If warpage is greater than maximum, replace the manifold.
25. INSPECT EXHAUST MANIFOLDS
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0196 inch)
If warpage is greater than maximum, replace the manifold.
26. INSPECT 12 POINTED HEAD CYLINDER HEAD BOLTS
Using vernier calipers, measure the tension portion diameter of the bolt.
Standard outside diameter: 8.95 - 9.05 mm (0.3524 - 0.3563 inch)
Minimum outside diameter: 8.75 mm (0.3445 inch)
If the diameter is less than minimum, replace the bolt.
REPLACEMENT
1. REPLACE VALVE GUIDE BUSHINGS
a. Gradually heat the cylinder head to 80 - 100°C (176 - 212°F).
b. Using SST and a hammer, tap out the guide bushing.
SST 09201-01055, 09950-70010 (09951-07100)
c. Using a caliper gauge, measure the bushing bore diameter of the cylinder head.
d. Select a new guide bushing (STD or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 10.313 mm (0.4060 inch), machine the bushing bore to the following dimension: 10.345 - 10.363 mm (0.4073 - 0.4080 inch)
If the bushing bore diameter of the cylinder head is greater than 10.363 mm (0.4080 inch), replace the cylinder head.
HINT: Different bushings are used for the intake and exhaust.
e. Gradually heat the cylinder head to 80 - 100°C (176 - 212°F).
f. Using SST and a hammer, tap in a new guide bushing to the specified protrusion height.
SST 09201-01055, 09950-70010 (09951-07100)
Protrusion height:
g. Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance between the guide bushing and valve stem.
2. REPLACE CAMSHAFT TIMING GEAR (VVT-i)
NOTICE: Do not remove or install the camshaft timing gear (VVT-i) beside changing VVT-i or the camshaft.
a. Mount the hexagon wrench head portion of the camshaft in a vise.
NOTICE: Be careful not to damage the camshaft.
b. Using a 46 mm socket wrench, remove the lock nut by turning it clockwise.
NOTICE:
- Remove it under the condition that the lock pin is operated and lock at the maximum delay angle position.
- The lock nut have LH threads.
- Never use any tool other than the socket wrench, otherwise that may result in deforming the cam angle rotor portion.
c. Remove the camshaft VVI-i.
HINT: In case of having difficulty to remove VVT-i, apply a slight hitting using a plastic-faced hammer and then remove it.
NOTICE: Never remove the 3 bolts on the gear.
d. Align the knock pin and knock pin groove and install VVT-i on the camshaft.
NOTICE: Install it under the condition that the lock pin is operated and lock at the maximum delay angle position.
e. Apply the engine oil on the nut, the placing surface of VVT-i and the screw portion.
HINT: Be sure to apply the oil, otherwise the prescribed torque cannot be obtained.
f. Using a 46 mm socket wrench, install and torque a new lock nut by turning it counterclockwise.
Torque: 150 Nm (1,530 kgf-cm, 110 ft. lbs.)
NOTICE:
- Must change the nuts to the new ones when to change VVT-i.
- The lock nut have LH threads.
- Never use any tool other than the socket wrench, otherwise that may result in deforming the cam angle rotor portion.
3. REPLACE SPARK PLUG TUBE GASKETS
a. Bend up the tab on the ventilation baffle plate which prevents the gasket from the slipping out.
b. Using a screwdriver and hammer, tap out the gasket.
c. Using needle-nose pliers, pry out the gasket.
d. Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.
SST 09608-03071
e. Apply a light coat of MP grease to the gasket lip.
f. Return the ventilation plate tab to its original position.