Part 1
Radiator, Air Cleaner Assb., TWC (LH And RH):
Throttle Body, Int. Manifold Assb., Related Wiring Harnesses:
Intake Manifold Assembly, Vacuum Tank Assb. For ACIS:
Intake Manifold Assb., Fuel Injectors And Related Components:
Timing Belt And Related Components:
Hoses, Switches, Sensors, And Various Components:
Cylinder Heads (RH And LH), And Related Components:
Camshafts,and VVTi:
Cylinder Heads (LH And RH), And Exhaust Manifolds (LH And RH):
DISASSEMBLY
1. REMOVE VALVE LIFTERS AND SHIMS
HINT: Arrange the valve lifters and shims in correct order.
2. REMOVE VALVES
a) Using SST, compress the valve spring and remove the 2 keepers.
SST 09202-70020 (09202-00010)
b) Remove these parts:
- Spring retainer
- Valve spring
- Valve
- Spring seat
HINT: Arrange the valves, valve springs, spring seats and spring retainers incorrect order.
c) Using needle-nose pliers, remove the oil seal.
INSPECTION
1. 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. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS
3. CLEAN CYLINDER HEAD
a) 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.
b) Using a wire brush, remove all the carbon from the combustion chambers.
NOTICE: Be careful not to scratch the cylinder block contact surface.
c) Using a valve guide bushing brush and solvent, clean all the guide bushings.
d) Using a soft brush and solvent, thoroughly clean the cylinder head.
4. INSPECT CYLINDER HEAD
a) 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 the maximum, replace the cylinder head.
b) 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.
c) Using vernier calipers, measure the thread outside diameter of the cylinder head bolt.
Standard outside diameter: 9.770 - 9.960 mm (0.3846 - 0.3921 inch)
Minimum outside diameter: 9.60 mm (0.3780 inch)
If the diameter is less than the minimum, replace the bolt.
5. CLEAN VALVES
a) Using a gasket scraper, chip off any carbon from the valve head.
b) Using a wire brush, thoroughly clean the valve.
6. 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 inside diameter measurement.
Standard oil clearance:
Maximum oil clearance:
If the clearance is greater than the maximum, replace the valve and guide bushing.
7. 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 the minimum, replace the valve.
d) Check the valve overall length.
Standard overall length:
Minimum overall length:
If the overall length is less than the 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 the minimum.
8. 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 these width: 1.0 - 1.4 mm (0.039 - 0.055 inch)
If not, correct the valve seats as follows:
- If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.
- If the seating is too low on the valve face, use 60° 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.
9. 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 the maximum, replace the valve spring.
b) Using vernier calipers, measure the free length of the valve spring.
Free length: 54.05 - 54.15 mm (2.1279 - 2.1319 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: 204 - 226 N (20.8 - 23.0 kgf, 45.9 - 50.7 lbs.) at 35.04 mm (1.3795 inch)
If the installed tension is not as specified, replace the valve spring.
10. INSPECT CAMSHAFTS
a) Inspect the circle runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.08 mm (0.0031 inch)
If the circle runout is greater than the maximum, replace the camshaft.
b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Minimum cam lobe height:
If the cam lobe height is less than the minimum, replace the camshaft.
c) Inspect the journal.
(1) Using a micrometer, measure the journal diameter for the camshaft bearing.
Journal diameter: 26.954 - 26.970 mm (1.0612 - 1.0618 inch)
If the journal diameter is not as specified, check the oil clearance.
(2) Using a micrometer, measure the journal diameter for the camshaft timing tube.
Journal diameter: 30.984 - 31.000 mm (1.2198 - 1.2205 inch)
11. INSPECT CAMSHAFT TIMING TUBE
HINT:
- There are 2 sizes of the camshaft timing tube journal diameter, green and red marks accordingly. The mark is on the face of the camshaft timing tube.
- When replacing the timing tube, select a new timing tube according to the mark on the cylinder head.
a) Using a micrometer, measure the journal diameter.
Journal diameter:
If the journal diameter is not as specified, check the oil clearance.
b) Install the timing tube to the intake camshaft, and check the timing tube turn smoothly.
If necessary, replace the timing tube and intake camshaft.
12. 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.
13. 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.
14. INSPECT CAMSHAFT AND CAMSHAFT TIMING TUBE JOURNAL OIL CLEARANCE
a) Install the camshaft timing tube to the intake camshaft.
b) Clean the bearing caps and journals.
c) Place the camshafts on the cylinder head.
d) Lay a strip of Plastigage across each of the journals.
e) Install the bearing caps.
NOTICE: Do not turn the camshaft.
f) Remove the bearing caps.
g) Measure the Plastigage at its widest point.
Standard oil clearance:
Maximum oil clearance:
If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
h) Completely remove the Plastigage.
i) Remove the camshafts.
j) Remove the camshaft timing tube from the intake camshaft.