General Specifications

GENERAL SPECIFICATIONS

INSPECTION AFTER REMOVAL

Camshaft Visual Check
Check camshaft for scratches, seizure and wear. Replace if necessary.

Camshaft Runout





1. Put V-block on precise flat bed and support No. 2 and No. 4 journal of camshaft as shown.
2. Set dial gauges vertically to No. 3 journal as shown.
3. Turn camshaft in one direction slowly by hand, measure the camshaft runout on the dial gauges.
^ Runout is the largest indicator reading after one full revolution.

Camshaft Runout
Standard Less than 0.02 mm (0.0008 inch)
Limit 0.05 mm (0.0020 inch)

4. If actual runout exceeds the limit, replace the camshaft.

Camshaft Cam Lobe Height





1. Measure camshaft cam lobe height as shown.
2. If wear has reduced the lobe height below specifications, replace the camshaft.

Camshaft Journal Clearance
Outer Diameter of Camshaft Journal





^ Measure outer diameter of camshaft journal as shown.

Standard outer diameter, No. 1 25.935 - 25.955 mm (1.0211 - 1.0218 inch)

Standard outer diameter, No. 2, 3, 4 23.445 - 23.465 mm (0.9230 - 0.9238 inch)

Inner Diameter of Camshaft Bracket





1. Tighten camshaft bracket bolt with specified torque.
2. Using inside micrometer, measure inner diameter "A" of camshaft bearing.

Standard inner diameter No. 1 26.000 - 26.021 mm (1.0236 - 1.0244 inch)

Standard inner diameter No. 2, 3, 4 23.500 - 23.521 mm (0.9252 - 0.9260 inch)

Calculation of Camshaft Journal Clearance
(Journal clearance) = (inner diameter of camshaft bracket) - (outer diameter of camshaft journal)

Standard No. 1 0.045 - 0.086 mm (0.0018 - 0.0034 inch)

Standard No. 2, 3, 4 0.035 - 0.076 mm (0.0014 - 0.0030 inch)

Limit 0.15 mm (0.0059 inch)

^ When out of the specified range, replace either or both camshaft and cylinder head.

NOTICE: Inner diameter of camshaft bracket is manufactured together with cylinder head. Replace the whole cylinder head assembly.

Camshaft End Play





1. Install the camshaft in the cylinder head.
2. Install dial gauge in thrust direction on front end of camshaft. Measure end play when camshaft is moved forward/backward (in direction to axis) as shown.

Standard 0.115 - 0.188 mm (0.0045 - 0.0074 inch)

Limit 0.24 mm (0.0094 inch)

^ If out of the specified range, replace with new camshaft and measure again.
^ If out of the specified range again, replace with new cylinder head.

Camshaft Sprocket Runout





1. Put V-block on precise flat bed and support No. 2 and No. 4 journal of camshaft as shown.
2. Install camshaft sprocket on camshaft.
3. Measure camshaft sprocket runout.

Runout Less than 0.15 mm (0.0059 inch)

4. If sprocket runout exceeds the limit, replace camshaft sprocket.

Valve Lifter





^ Check if the surface of the valve lifter has any excessive wear or cracks, replace as necessary.

Valve Lifter Clearance
Outer Diameter of Valve Lifter





^ Measure the outer diameter of the valve lifter.
^ If out of the specified range, replace the valve lifter.

Valve Lifter Bore Diameter





^ Using inside micrometer, measure diameter of valve lifter bore of cylinder head.
^ If out of the specified range, replace the cylinder head assembly.

Calculation of Valve Lifter Clearance
^ (Valve lifter clearance) = (hole diameter for valve lifter) - (outer diameter of valve lifter) Refer to "Valve Lifter".
^ If out of specified range, replace either or both valve lifter and cylinder head assembly.

Inspection after Installation
INSPECTION OF CAMSHAFT SPROCKET (INT) OIL GROOVE

CAUTION:
^ Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT II and it is directed according to inspection procedure of Engine Controls.
^ Check when engine is cold so as to prevent burns from any splashing engine oil.

1. Check engine oil level. Refer to "OIL LEVEL".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking.
a. Release fuel pressure. Refer to "FUEL PRESSURE RELEASE".
b. Disconnect ignition coil and injector harness connectors if practical.
3. Remove IVT control solenoid valve.





4. Crank engine, and then make sure that engine oil comes out from IVT control cover oil hole. End cranking after checking.

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

CAUTION:
^ Engine oil may squirt from IVT control solenoid valve installation hole during cranking. Use a shop cloth to prevent engine oil from splashing on worker, engine components and vehicle.
^ Do not allow engine oil to get on rubber components such as drive belts or engine mount insulators. Immediately wipe off any splashed engine oil.

5. Clean oil groove between oil strainer and IVT control solenoid valve if engine oil does not come out from IVT control cover oil hole.
6. Remove components between IVT control solenoid valve and camshaft sprocket (INT), and then check each oil groove for clogging.
^ Clean oil groove if necessary.
7. After inspection, installation of the remaining components is in the reverse order of removal.

Valve Clearance
CHECKING





^ Perform inspection as follows after removal, installation or replacement of camshaft or valve related parts, or if there is unusual engine conditions regarding valve clearance.

Check valve clearance while engine is cold and not running.
1. Remove the air duct with air cleaner case, collectors, hoses, wires, harnesses, and connectors.
2. Remove the intake manifold collectors.
3. Remove the ignition coils and spark plugs.
4. Remove the rocker covers.





5. Set No. 1 cylinder at TDC on its compression stroke.
^ Align pointer with TDC mark on crankshaft pulley.





^ Check that the valve lifters on No. 1 cylinder are loose and valve lifters on No. 4 are tight. If not, turn the crankshaft one full revolution (360°) and align as shown.














6. Check only the valves as shown.
^ Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
^ Record any valve clearance measurements which are out of specification. They will be used later to determine the required replacement lifter size.

Valve Clearance for Checking (cold)
Intake 0.26 - 0.34 mm (0.010 - 0.013 inch)
Exhaust 0.29 - 0.37 mm (0.011 - 0.015 inch)

7. Turn crankshaft 240°.
8. Set No. 3 cylinder at TDC on its compression stroke.








9. Check only those valves as shown.
10. Turn the crankshaft 240° and align as above.
11. Set No. 5 cylinder at TDC on its compression stroke.








12. Check only those valves as shown.
13. If all valve clearances are within specification, install the following components. If the valve clearances are out of specification, adjust the valve clearances.
^ Intake manifold collectors
^ Rocker covers
^ All spark plugs
^ All ignition coils

VALVE ADJUSTING

CAUTION: Adjust valve clearance while engine is cold.

NOTE:
^ Perform adjustment by selecting the correct head thickness of the valve lifter (adjusting shims are not used).
^ The specified valve lifter thickness is the dimension at normal temperatures. Ignore dimensional differences caused by temperature. Use specifications for hot engine condition to confirm valve clearances.

1. Remove the camshaft.
2. Remove the valve lifter that was measured as being outside the standard specifications.





3. Measure the center thickness of the removed lifter with a micrometer, as shown.





4. Use the equation below to calculate the replacement valve lifter thickness.

Valve lifter thickness calculation equation: t = t1 + (C1 - C2)
t = thickness of the replacement lifter
t1 = thickness of the removed lifter
C1 = measured valve clearance
C2 = standard valve clearance
^ The thickness of the new valve lifter can be identified by the stamp mark on the reverse side (inside the lifter).
^ Available thickness of the valve lifter (factory setting) 7.88 - 8.36 mm (0.3102 - 0.3291 inch), in 0.02 mm (0.0008 inch) increments, in 25 sizes (intake / exhaust).

Value lifter thickness:
Intake 0.30 mm (0.012 inch)
Exhaust 0.33 mm (0.013 inch)

5. Install the selected replacement valve lifter.
6. Install the camshaft.
7. Rotate the crankshaft a few turns by hand.
8. Confirm that the valve clearances are within specification.





9. After the engine has been run to full operating temperature, confirm that the valve clearances are within specification.