Part 2

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

INSPECTION(continued)

21. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrate, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head.

22. INSPECT INTAKE VALVE SEAT
(a) Apply a light coat of Prussian blue (or white lead) to the valve face.
(b) Lightly press the valve face against the valve seat.
(c) Check the valve face and valve seat by using the following procedure.
(1) If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.
(2) If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat.
(3) Check that the valve seat contacts in the middle of the valve face with the width between 1.0 and 1.4 mm (0.039 and 0.055 inch).

23. INSPECT EXHAUST VALVE SEAT
(a) Apply a light coat of Prussian blue (or white lead) to the valve face.
(b) Lightly press the valve face against the valve seat.
(c) Check the valve face and valve seat by using to the following procedure.
(1) If Prussian blue appears around the entire valve face, the valve face is concentric. If not, replace the valve.
(2) If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat.
(3) Check that the valve seat contacts in the middle of the valve face with the width between 1.0 and 1.4 mm (0.039 and 0.055 inch).

24. INSPECT CAMSHAFT
(a) Check the camshaft for 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 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: 42.855 to 42.955 mm (1.6872 to 1.6911 inch)
Minimum cam lobe height: 42.855 mm (1.6872 inch)
If the cam lobe height is less than the minimum, replace the camshaft.

Standard journal diameter:

If the journal diameter is not as specified, check the oil clearance.

25. INSPECT NO.2 CAMSHAFT
(a) Check the camshaft for 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 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: 42.854 to 42.954 mm (1.687 to 1.6911 inch)
Minimum cam lobe height: 42.854 mm (1.6872 inch)
If the cam lobe height is less than the minimum, replace the camshaft.

Standard journal diameter:

If the journal diameter is not as specified, check the oil clearance.

26. 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: 0.10 to 0.24 mm (0.004 to 0.009 inch)
Maximum thrust clearance: 0.26 mm (0.010 inch)
If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

27. INSPECT CAMSHAFT 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 journals.
(d) Install the bearing caps.
Torque: 16 Nm (160 kgf-cm, 11 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: 0.08 mm (0.003 inch)
If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the cylinder head.
(g) Completely remove the Plastigage.

28. INSPECT INNER COMPRESSION SPRING
(a) Using vernier calipers, measure the free length of the inner compression spring.
Free length: 48.53 mm (1.9106 inch)
If the free length is not as specified, replace the spring.

(b) Using a steel square, measure the deviation of the inner compression spring.
Maximum deviation: 1.5 mm (0.059 inch)
Maximum angle (reference): 2°
If the deviation is greater than the maximum, replace the spring.

29. INSPECT INTAKE VALVE
(a) Using vernier calipers, measure the valve's overall length.
Standard overall length: 106.26 mm (4.1835 inch)
Minimum overall length: 105.96 mm (4.1716 inch)
If the overall length is less than the minimum, replace the valve.

(b) Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 inch)

(c) Using vernier calipers, measure the valve head margin thickness.
Standard margin thickness: 1.05 to 1.45 mm (0.0413 to 0.0571 inch)
Minimum margin thickness: 0.50 mm (0.0197 inch)
Thickness If the margin thickness is less than the minimum, replace the valve.

30. INSPECT EXHAUST VALVE
(a) Using vernier calipers, measure the valve's overall length.
Standard overall length: 106.74 mm (4.2024 inch)
Minimum overall length: 106.44 mm (4.1905 inch)
If the overall length is less than the minimum, replace the valve.

(b) Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter: 5.465 to 5.480 mm (0.2151 to 0.2157 inch)

(c) Using vernier calipers, measure the valve head margin thickness.
Standard margin thickness: 1.2 to 1.6 mm (0.0472 to 0.0630 inch)
Minimum margin thickness: 0.50 mm (0.0197 inch)
If the margin thickness is less than the minimum, replace the valve.

31. INSPECT VALVE GUIDE BUSHING
(a) Using a caliper gauge, measure the inside diameter of the guide bush.
Bush inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 inch)
(b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.
Standard oil clearance:
0.025 to 0.060 mm (0.0010 to 0.0024 inch) (Intake)
0.030 to 0.065 mm (0.0012 to 0.0026 inch) (Exhaust)
Maximum oil clearance:
0.08 mm (0.0032 inch) (Intake)
0.10 mm (0.0039 inch) (Exhaust)

HINT:
^ If the clearance is greater than the maximum, replace the intake valve and intake guide bush.
^ If the clearance is greater than the maximum, replace the exhaust valve and exhaust guide bush.

32. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.150 to 0.350 mm (0.0059 to 0.0138 inch)
Maximum thrust clearance: 0.40 mm (0.016 inch)
If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft.
33. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly.

HINT: The matchmarks on the connecting rods and caps are for ensuring the correct reassembly.

(b) Remove the 2 connecting rod cap bolts.
(c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

HINT: Keep the lower bearing inserted to the connecting rod cap.

(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scratches.

(f) Lay a strip of Plastigage on the crank pin.

(g) Check that the front mark of the connecting rod cap is facing forward.

(h) Install the connecting rod cap.

NOTICE: Do not turn the crankshaft.

(i) Remove the 2 bolts and connecting rod cap (see steps (b) and (c) above).
(j) Measure the Plastigage at its widest point.
Standard oil clearance: 0.024 to 0.049 mm (0.0009 to 0.0019 inch)
Maximum oil clearance: 0.066 mm (0.0026 inch)
If the oil clearance is greater than the maximum, replace the connecting rod bearings. If necessary, replace the crankshaft.

HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. Each bearing's standard thickness is indicated by a 1, 2 and 3 mark on its surface.

Reference

Crankshaft pin diameter:

Standard bearing center wall thickness:

(k) Completely remove the Plastigage.

34. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.020 to 0.220 mm (0.0008 to 0.0087 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft.
Thrust washer thickness: 2.440 to 2.490 mm (0.0961 to 0.0980 inch)

35. CLEAN WITH PIN PISTON SUB-ASSEMBLY
(a) Using a gasket scraper, remove the carbon from the piston top.

(b) Using a groove cleaning tool or broken ring, clean the piston ring grooves.

(c) Using solvent and a brush, thoroughly clean the piston.

NOTICE: Do not use a wire brush.

36. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Check the oil nozzles for damage or clogging. If necessary, replace the oil nozzle.

37. INSPECT BALANCE SHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
Standard thrust clearance: 0.07 to 0.13 mm (0.0027 to 0.0051 inch)
Maximum thrust clearance: 0.20 mm (0.0079 inch)
If the thrust clearance is greater than the maximum, replace the balance shaft thrust washer. If necessary, replace the balance shaft.

38. INSPECT CYLINDER BLOCK FOR FLATNESS
(a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.
Maximum warpage: 0.05 mm (0.0020 inch)
If the warpage is greater than the maximum, replace the cylinder block.

(b) Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 4 cylinders. If necessary, replace the cylinder block.

39. INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore diameter at positions A in the thrust and axial directions.
Standard diameter: 94.990 to 95.003 mm (3.7398 to 3.7403 inch)
Maximum difference diameter: 0.2 mm (0.008 inch)
If the diameter is greater than the maximum, rebore all the 4 cylinders. If necessary, replace the cylinder block.

(b) Inspect the cylinder ridge.
If the wear is less than 0.2 mm (0.008 inch), using a ridge reamer, grind the top of the cylinder.

40. CLEAN CYLINDER BLOCK
(a) Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
(b) Using a soft brush and solvent, thoroughly clean the cylinder block.