Inspection

INSPECTION AND CLEANING OF CYLINDER HEAD COMPONENTS
1. CLEAN TOP OF PISTONS AND TOP OF BLOCK
(a) Turn the crankshaft and bring each piston to top dead center. Scrape the carbon from the piston top.
(b) Remove all gasket material from the top of the block. Blow carbon and oil from the bolt holes.

2. CLEAN COMBUSTION CHAMBER
Using a wire brush, remove all the carbon from the combustion chambers.

NOTICE: Be careful not to scratch the head gasket contact surface.

3. CLEAN VALVE GUIDES
Using a valve guide brush and solvent, clean all valve guides.

4. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all gasket material from the manifold and head surfaces.

NOTICE: Do not scratch the surfaces.

5. CLEAN CYLINDER HEAD
Using a soft brush and solvent, clean the head.

NOTICE: Do not clean the head in a hot tank as this will seriously damage it.

6. INSPECT HEAD FOR FLATNESS
(a) Using a precision straightedge and thickness gauge, check that the head and manifold surfaces are not warped.
(b) Measure warpage along the four edges and diagonally as illustrated.
Maximum head surface warpage: 0.15 mm (0.0059 in.)
Maximum manifold surface warpage: 0.20 mm (0.0079 in.)
If warpage is greater than specified value, replace the head.

7. INSPECT CYLINDER HEAD FOR CRACKS
Using a dye penetrant, check the combustion chamber, intake and exhaust ports, head surface and the top of the head for cracks.
If a crack is found, replace the head.

8. CLEAN VALVES
Use an old valve to chip any carbon from the valve head. Using a gasket scraper, clean the valve thoroughly.

9. INSPECT VALVE STEM GUIDE WEAR
(a) Using a dial indicator or telescoping gauge, measure the inside diameter of the valve guide.
Standard inside diameter: 8.01 - 8.03 mm (0.3154 - 0.3161 in.)

(b) Using a micrometer, measure the diameter of the valve stem.
Standard valve stem diameter:
Intake 7.970 - 7.985 mm (0.3138 - 0.3144 in.)
Exhaust 7.965 - 7.980 mm (0.3136 - 0.3142 in.)
(c) Subtract the valve stem measurement from the valve guide measurement.
Standard oil clearance:
Intake 0.025 - 0.060 mm (0.0010 - 0.0024 in.)
Exhaust 0.030 - 0.065 mm (0.0012 - 0.0026 in.)
Maximum oil clearance:
Intake 0.08 mm (0.0031 in.)
Exhaust 0.10 mm (0.0039 in.)
If the clearance is greater than following values, replace the valve and guide:

10. IF NECESSARY, REPLACE VALVE GUIDE
(a) Using a brass bar and hammer, break the valve guide.

(b) Heat the cylinder head to approx. 90°C (194°F).

(d) Using a caliper gauge, measure the valve guide bore of the cylinder head.

(e) Select a new valve guide.
If the valve guide bore of the cylinder head is more than 13.018 mm (0.5125 in.), machine the bore to the following dimension.
Rebored valve guide bushing bore dimension (cold): 13.050 - 13.068 mm (0.5138 - 0.5145 in.)

(f) Heat the cylinder head to approx. 90°C (194°F)
(g) Using SST and hammer, drive in a new valve guide until the snap ring makes contact with the cylinder head. SST 09201-60011

(h) Using a sharp 8 mm reamer, ream the valve guide to obtain the specified clearance between the guide and new valve.
Intake clearance: 0.025 - 0.06 mm (0.0010 - 0.0024 in.)
Exhaust clearance: 0.030 - 0.065 mm (0.0012 - 0.0026 in.)

11. INSPECT AND GRIND VALVES
(a) Grind the valves only enough to remove pits and carbon.
Make sure the valves are ground at the correct valve face angle.
Valve face angle: 44.5°
(b) Check the valve head margin.
Minimum margin: 0.6 mm (0.024 in.)
If the valve head margin is less than specified, replace the valve.

(c) 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 more than 0.5 mm (0.020 in.)
Standard overall length:
Intake 113.5 mm (4.468 in.)
Exhaust 112.4 mm (4.425 in.)

12. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° cutter, resurface the valve seats. Remove enough metal to clean the seats.

(b) Check the valve seating position.
Apply a thin coat of prussian blue (or white lead) to the valve face. Install the valve. Lightly press the valve against the seal Do not rotate the 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 seat are concentric. If not, resurface the seat.

- Check that the seat contact is on the middle of the valve face with the following width: 1.2 - 1.6 mm (0.047 - 0.063 in.)
If not, correct the valve seat as follows:
If seating is too high on the valve face, use 30°and 45° cutters to correct the seat.
If seating is too low on the valve face, use 60° (IN) or 65° (EX) and 45° cutters to correct the seat.

(d) Hand-lap the valve and valve seat together with abrasive compound.
(e) Clean the valve and valve seat after hand-lapping.

13. INSPECT VALVE SPRINGS
(a) Using a steel square, check the squareness of the valve springs.
Maximum allowable: 1.6 mm (0.063 in.)
If a spring is out of square more than maximum allowable, replace the spring.

(b) Measure the free height of all springs.
Free height: 48.5 mm (1.909 in.)
Replace any spring that is not correct.

(c) Using a spring tester, check the tension of each spring at the specified installed height.
Installed height: 40.5 mm (1.594 in.)
Standard installed tension: 30.0 kg (66.1 lb, 294 N)
Minimum installed tension: 28.5 kg (62.8 lb, 279 N)
If the installed tension is less than minimum, replace the spring.

14. INSPECT CAMSHAFT AND BEARING CAPS
(a) Using a micrometer, measure the cam lobes.
Standard intake lobe height: 42.63-42.72 mm (1.6783 - 1.6819 in.)
Standard exhaust lobe height: 42.69-42.78 mm (1.6807 - 1.6842 in.)
If the lobe height is less than standard allowable, the camshaft is worn and must be replaced.

(b) Place the camshaft on V-blocks and measure the runout at the center journal.
Maximum circle runout: 0.2 mm (0.008 in.) If the runout is greater than maximum allowable, replace the camshaft.

(d) Measure the camshaft journal oil clearance.
- Clean the bearing caps and camshaft journal.
- Lay a strip of Plastigage across each journal.

- Install the correct numbered bearing cap on each journal with the arrows pointing toward the front. Torque each bolt.
Torque: 200 kg-cm (14 ft-lb, 20 N.m)

HINT: Do not turn the camshaft while the Plastigage is in place.

- Remove the caps. Measure the Plastigage at its widest point.
Standard clearance: 0.01 - 0.05 mm (0.0004 - 0.0020 in.)
Maximum clearance: 0.1 mm (0.004 in.)
If clearance is greater than maximum, replace the head and/or camshaft.
- Clean out the pieces of Plastigage from the bearings and journals.

15. INSPECT ROCKER ARMS
Check the clearance between the rocker arms and shaft by moving the rocker arms as shown. Little or no movement should be felt.
If movement is felt, disassemble the rocker arm assembly and measure the oil clearance as follows:

(a) Disassemble rocker arm assembly.
- Remove the three screws.
- Slide the rocker stands~ springs and rocker arms off the shafts.
(b) Using a dial indicator, measure the inside diameter of the rocker arm.
Standard inside diameter: 16.000 - 16.018 mm (0.6299 - 0.6306 in.)

(c) Using a micrometer, measure the outside diameter of the shaft.
Standard diameter: 15.97 - 15.99 mm 0.6287 - 0.6295 in.)
(d) Subtract the shaft diameter from the rocker arm diameter.
Standard oil clearance: 0.01 - 0.05 mm (0.0004 - 0.0020 in.)
Maximum oil clearance: 0.08 mm (0.0031)
If the oil clearance is not within specification, replace the rocker arm and/or shaft.

(e) Assemble the rocker arm assembly as shown, and install the three screws.

HINT: All rocker arms are the same but all rocker stands are different and must be assembled in the correct order.

16. INSPECT INTAKE AIR INTAKE CHAMBER, AND EXHAUST MANIFOLDS
Using a precision straightedge and feeler gauge, check the surfaces contacting the cylinder head for warpage. If warpage is greater than maximum, replace the manifold.
Maximum intake warpage: 0.2 mm (0.008 in.)
Maximum exhaust warpage: 0.7 mm (0.028 in.)
Maximum air intake chamber warpage: 0.2 mm (0.008 in.)