Part 2

CYLINDER HEAD continued

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

COMPONENTS (Part 12):

COMPONENTS (Part 13):

COMPONENTS (Part 14):

COMPONENTS (Part 15):

COMPONENTS (Part 16):

COMPONENTS (Part 17):

13. INSPECT NO. 2 CAMSHAFT

(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: 0.03 mm (0.0012 in.)
If the circle runout is greater than the maximum, replace the No. 2 camshaft.

(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height: 42.63 to 42.73 mm (1.6783 to 1.6822 in.)
Minimum cam lobe height: 42.48 mm (1.6724 in.)
If the cam lobe height is less than the minimum, replace the No. 2 camshaft.

(c) Using a micrometer, measure the journal diameter.
Standard journal diameter: 26.954 to 26.970 mm (1.0612 to 1.0618 in.)
If the journal diameter is not as specified, check the oil clearance.

(d) Check the oil clearance.
(1) Clean the bearing caps and journals.
(2) Check the bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set.
(3) Place the No. 2 camshaft on the cylinder head.
(4) Lay a strip of Plastigage across each of the journals.
(5) Install the bearing caps.

NOTICE: Be careful not to turn the No. 2 camshaft.

(6) Remove the bearing caps.

(7) Measure the Plastigage at its widest point.
Standard oil clearance: 0.030 to 0.071 mm (0.0012 to 0.0028 in.)
Maximum oil clearance: 0.100 mm (0.0039 in.)
If the oil clearance is greater than the maximum, replace the No. 2 camshaft. If necessary, replace the bearing caps and cylinder head as a set.
(8) Completely remove the Plastigage.
(9) Remove the No. 2 camshaft.

(e) Check the thrust clearance.
(1) Install the No. 2 camshaft.
(2) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance: 0.030 to 0.070 mm (0.0012 to 0.0028 in.)
Maximum thrust clearance: 0.10 mm (0.0039 in.)
If the thrust clearance is greater than the maximum, replace the No. 2 camshaft. If necessary, replace the bearing caps and cylinder head as a set.
(3) Remove the No. 2 camshaft.

14. INSPECT NO. 3 CAMSHAFT SUB-ASSEMBLY

(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height: 42.61 to 42.71 mm (1.6776 to 1.6815 in.)
Minimum cam lobe height: 42.46 mm (1.6717 in.)
If the cam lobe height is less than the minimum, replace the No. 3 camshaft.

(c) Inspect the journal diameter of the No. 3 camshaft.
(1) Using a micrometer, measure the journal diameter of the No. 3 camshaft for the camshaft bearing.
Standard journal diameter: 26.954 to 26.970 mm (1.0612 to 1.0618 in.)
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.
Standard journal diameter: 30.984 to 31.000 mm (1.2198 to 1.2205 in.)
If the journal diameter is not as specified, check the oil clearance.

(d) Inspect the journal diameter of the camshaft timing tube.
(1) Using a micrometer, measure the journal diameter.
Standard journal diameter: 39.955 to 39.964 mm (1.5730 to 1.5734 in.)
If the journal diameter is not as specified, check the oil clearance.
(2) Install the drive gear to the camshaft timing tube.

(e) Install the timing tube to the No. 3 camshaft, and check that the timing tube turns smoothly. If necessary, replace the timing tube and No. 3 camshaft.

(f) Check the oil clearance.
(1) Clean the bearing caps and journals.
(2) Check the bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set.
(3) Place the No. 3 camshaft on the cylinder head.
(4) Lay a strip of Plastigage across each of the journals.
(5) Install the bearing caps.

NOTICE: Be careful not to turn the camshaft.

(6) Remove the bearing caps.

(7) Measure the Plastigage at its widest point.

Standard oil clearance:

Maximum oil clearance:

If the oil clearance is greater than the maximum, replace the No. 3 camshaft and timing tube. If necessary, replace the bearing caps and cylinder head as a set.
(8) Completely remove the Plastigage.
(9) Remove the No. 3 camshaft.

(g) Check the thrust clearance.
(1) Install the No. 3 camshaft.
(2) Using a dial indicator, measure the thrust clearance while moving the No. 3 camshaft back and forth.
Standard thrust clearance: 0 to 0.040 mm (0 to 0.0016 in.)
Maximum thrust clearance: 0.12 mm (0.0047 in.)
If the thrust clearance is greater than the maximum, replace the No. 3 camshaft. If necessary, replace the bearing caps and cylinder head as a set.
(3) Remove the No. 3 camshaft.

(h) Check the gear backlash.
(1) Install the No. 3 camshaft and No. 4 camshaft without installing the camshaft sub-gear and front bearing cap.
(2) Using a dial indicator, measure the backlash.
Standard backlash: 0.020 to 0.200 mm (0.0008 to 0.0079 in.)
Maximum backlash: 0.30 mm (0.0118 in.)
If the backlash is greater than the maximum, replace the drive gear and No. 4 camshaft.
(i) Remove the No. 3 camshaft and No. 4 camshaft.
(j) Remove the camshaft timing tube from the No. 3 camshaft.
(k) Remove the drive gear from the camshaft timing tube.

15. INSPECT NO. 4 CAMSHAFT SUB-ASSEMBLY

(c) Using a micrometer, measure the journal diameter.
Standard journal diameter: 26.954 to 26.970 mm (1.0612 to 1.0618 in.)
If the journal diameter is not as specified, check the oil clearance.

(d) Check the oil clearance.
(1) Clean the bearing caps and journals.
(2) Check the bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set.
(3) Place the No. 4 camshaft on the cylinder head.
(4) Lay a strip of Plastigage across each of the journals.
(5) Install the bearing caps.

NOTICE: Be careful not to turn the No. 4 camshaft.

(6) Remove the bearing caps.

(7) Measure the Plastigage at its widest point.
Standard oil clearance: 0.030 to 0.071 mm (0.0012 to 0.0028 in.)
Maximum oil clearance: 0.100 mm (0.0039 in.)
If the oil clearance is greater than the maximum, replace the No. 4 camshaft. If necessary, replace the bearing caps and cylinder head as a set.
(8) Completely remove the Plastigage.
(9) Remove the No. 4 camshaft.

(e) Check the thrust clearance.
(1) Install the No. 4 camshaft.
(2) Using a dial indicator, measure the thrust clearance while moving the No. 4 camshaft back and forth.
Standard thrust clearance: 0.030 to 0.070 mm (0.0012 to 0.0028 in.)
Maximum thrust clearance: 0.10 mm (0.0039 in.)
If the thrust clearance is greater than the maximum, replace the No. 4 camshaft. If necessary, replace the bearing caps and cylinder head as a set.
(3) Remove the No. 4 camshaft.

16. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier caliper, measure the thread outside diameter of the bolt.
Standard outside diameter: 9.810 to 9.960 mm (0.3862 to 0.3921 in.)
Minimum outside diameter: 9.70 mm (0.3819 in.)
If the diameter is less than the minimum, replace the bolt.

REPLACEMENT

1. REMOVE INTAKE VALVE GUIDE BUSH

(a) Gradually heat the cylinder head to approximately 80 to 100° C (176 to 212°F).

(b) Using SST and a hammer, tap out the guide bush.
SST 09201-10000, 09950-70010 (09951-07100)

2. INSTALL INTAKE VALVE GUIDE BUSH

(a) Using a caliper gauge, measure the bush bore diameter of the cylinder head.

(b) Select a new guide bush (STD or O/S 0.05).

Standard bush bore diameter:

HINT:
^ If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore diameter to between 10.335 and 10.356 mm (0.4068 to 0.4077 in.).
^ If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

HINT: Different bushes are used for the intake and exhaust.

Standard intake bush length: 34.5 mm (1.358 in.)
(c) Gradually heat the cylinder head to approximately 80 to 100°C (176 to 212°F).

(d) Using SST and a hammer, tap in a new guide bush to the specified protrusion height.
SST 09201-10000, 09950-70010 (09951-07100)
Standard protrusion height (H): 9.2 to 9.8 mm (0.362 to 0.386 in.)

(e) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem.

3. REMOVE EXHAUST VALVE GUIDE BUSH

(a) Gradually heat the cylinder head to approximately 80 to 100°C (176 to 212°F).

(b) Using SST and a hammer, tap out the guide bush.
SST 09201-10000, 09950-70010 (09951-07100)

4. INSTALL EXHAUST VALVE GUIDE BUSH

(a) Using a caliper gauge, measure the bush bore diameter of the cylinder head.

(b) Select a new guide bush (STD or O/S 0.05).

Standard bush bore diameter:

HINT:
^ If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore diameter to between 10.335 and 10.356 mm (0.4068 to 0.4077 in.).
^ If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

HINT: Different bushes are used for the intake and exhaust.

Standard exhaust bush length: 40.5 mm (1.594 in.)

(c) Gradually heat the cylinder head to approximately 80 to 100° C (176 to 212°F).

(d) Using SST and a hammer, tap in a new guide bush to the specified protrusion height.
SST 09201-01055, 09950-70010 (09951-07100)
Standard protrusion height (H): 8.2 to 8.8 mm (0.323 to 0.346 in.)

(e) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem.