Part 1

ENGINE UNIT

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):

INSPECTION

1. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier caliper, measure the outside thread diameter of the bolt.
Measuring point: 73.0 mm (2.87 in.)
Standard outside diameter: 10.85 to 11.0 mm (0.427 to 0.433 in.)
Minimum outside diameter: 10.7 mm (0.421 in.)

HINT:
If a visual check reveals no excessively thin areas, check the center of the bolt (see illustration) and find the area that has the lowest diameter.
If the diameter is less than the minimum, replace the cylinder head bolt.

2. CLEAN CYLINDER HEAD SUB-ASSEMBLY
(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 combustion chambers.

(d) Using a soft brush and solvent, thoroughly clean the cylinder head.

3. INSPECT CYLINDER HEAD SUB-ASSEMBLY
(a) Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces of the cylinder block and manifolds.

Standard warpage:

Maximum warpage:

If the warpage is greater than the maximum, replace the cylinder head sub-assembly.

(b) Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks.
If there are cracks, replace the cylinder head sub-assembly.

4. CLEAN VALVE
(a) Using a gasket scraper, chip off any carbon from the valve head.
(b) Using a wire brush, thoroughly clean the valve.

5. INSPECT VALVE
(a) Using a micrometer, measure the diameter of the valve stem.
(1) Using a micrometer, measure the diameter of the valve stem.

Standard valve stem diameter:

(b) Inspect the valve face angle.
(1) Grind the valve enough to remove pits and carbon.
(2) Check that the valve is ground to the correct valve face angle.
Standard valve face angle: 44.5°

(c) Using a vernier caliper, measure the valve head margin thickness.
(1) Using a vernier caliper, check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.0394 in.)
Minimum margin thickness: 0.5 mm (0.0197 in.)
If the margin thickness is less than the minimum, replace the valve.

(d) Using a vernier caliper, measure the valve's overall length.
(1) Using a vernier caliper, check the overall length.

Standard overall length:

Minimum overall length:

If the overall length is less than the minimum, replace the valve.

(e) Inspect the valve stem tip.
(1) Check the surface of the valve stem tip for wear.

NOTICE: Do not grind off more than the minimum length.

If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.

6. CLEAN VALVE SEAT
(a) Using a 45° carbide cutter, resurface the valve seats.
(b) Clean the valve seats.

7. INSPECT VALVE SEAT
(a) Apply a light coat of Prussian blue to the valve face.
(b) Lightly press the valve face against the valve seat.

NOTICE: Do not rotate the valve.

(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 seat contacts the middle of the valve face with the width below.
Standard width: 1.0 to 1.4 mm (0.0394 to 0.0551 in.)

8. INSPECT INNER COMPRESSION SPRING
(a) Using a steel square, measure the deviation of the inner compression spring.
Maximum deviation: 2.0 mm (0.0787 in.)
If the deviation is greater than the maximum, replace the inner compression spring.

(b) Using a vernier caliper, measure the free length of the inner compression spring.
Standard free length: 47.80 mm (1.88 in.)
If the free length is not as specified, replace the inner compression spring.

(c) Using a spring tester, measure the tension of the inner compression spring at the specified installed length.
Installed tension: 186 to 206 N (19 to 21 kgf, 42 to 46 lbf) at 33.3 mm (1.31 in.)
If the installed tension is not as specified, replace the inner compression spring.

9. INSPECT VALVE GUIDE BUSH OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the guide bush.
Standard bush inside diameter: 5.51 to 5.53 mm (0.217 to 0.218 in.)
(b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.

Standard oil clearance:

Maximum oil clearance (Part 1):

Maximum oil clearance (Part 2):

If the oil clearance is greater than the maximum, replace the valve and valve guide bush.

10. INSPECT VALVE LIFTER
(a) Using a micrometer, measure the valve lifter diameter.
Standard valve lifter diameter: 30.966 to 30.976 mm (1.219 to 1.220 in.)
If the result is not as specified, replace the valve lifter.

11. INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
Standard lifter bore diameter: 31.009 to 31.025 mm (1.220 to 1.221 in.)
(b) Subtract the valve lifter diameter measurement (see "INSPECT VALVE LIFTER" procedure) from the lifter bore diameter measurement.
Standard oil clearance: 0.033 to 0.059 mm (0.00130 to 0.00232 in.)
Maximum oil clearance: 0.08 mm (0.00315 in.)
If the oil clearance is greater than the maximum, replace the valve lifter.
If necessary, replace the cylinder head.

12. 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: 0.04 to 0.09 mm (0.00157 to 0.00354 in.)
Maximum thrust clearance: 0.11 mm (0.00433 in.)
If the thrust clearance is greater than the maximum, replace the camshafts.
If necessary, replace the camshaft bearing caps and cylinder head as a set.

13. INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the camshaft bearing caps, camshaft bearings and camshaft journals.
(b) Install the camshaft bearing.
(c) Place the camshafts on the cylinder head.
(d) Lay a strip of Plastigage across each of the camshaft journals.
(e) Install the camshaft bearing caps.

NOTICE: Do not turn the camshafts.

(f) Remove the camshaft bearing caps.

(g) Measure the Plastigage at its widest point.

Standard oil clearance (for Cylinder head RH):

Standard oil clearance (for Cylinder head LH):

Maximum oil clearance (for Cylinder head RH):

Maximum oil clearance (for Cylinder head LH):

If the oil clearance is greater than the maximum, replace the camshaft bearings and/or camshaft.
If necessary, replace the camshaft bearing caps and cylinder head together.

Reference:

(h) Remove the Plastigage completely.
(i) Remove the camshafts.
(j) Remove the camshaft bearing.

14. INSPECT CAMSHAFTS
(a) Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the runout at the center journal.
Maximum runout: 0.06 mm (0.00236 in.)
If the runout is greater than the maximum, replace the camshaft.

(b) Inspect the cam lobes.
(1) 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.

Standard journal diameter:

If the journal diameter is not as specified, check the oil clearance.
15. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Fix the intake camshaft with a vise.

NOTICE: Be careful not to damage the camshaft.

(b) Align the knock pin hole in the camshaft timing gear with the knock pin of the camshaft, and install the camshaft timing gear with the bolt.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
(c) Confirm the camshaft timing gear is locked.

(d) Release the lock pin.
(1) Cover 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

HINT: One of the 2 grooves on the cam journal is for retard side paths (upper) and the other is for advance side paths (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with rubber pieces before wrapping the cam journal with tape.

(2) Prick a hole in the tape placed on the advance side path. Prick a hole in the retard side path on the opposite side of that advance side path, as shown in the illustration.

(3) Apply about 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the two broken paths (the advance side path and the retard side path).

NOTICE: Cover the paths with a cloth to avoid oil splashing.

(4) Confirm that the camshaft timing gear rotates in the advance direction when reducing the air pressure applied to the retard path.

HINT: When the lock pin is released, the camshaft timing gear rotates in the advance direction.

(5) When the camshaft timing gear comes to the most advanced position, release the air pressure from the retard side path, and then release the air pressure from the advance side path.

NOTICE: The camshaft timing gear occasionally shifts to the retard side abruptly if air compression of the advanced side path is released first. This often results in the breakage of the lock pin.

(e) Check for smooth rotation.
(1) Except the position where the lock pin meets at the most retard angle, turn the camshaft timing gear back and forth and check the movable range and that there is no disturbance.
Standard: Movable smoothly in the range of about 31°

NOTICE: Be sure to perform this check by hand, instead of with air pressure.

(f) Check the lock in the most retarded position.
(1) Confirm that the camshaft timing gear is locked at the most retarded position.

(g) Remove the set bolt and camshaft timing gear.

NOTICE: Be sure not to remove the other 3 bolts.

16. INSPECT CONNECTING ROD BOLT
(a) Using a vernier caliper, measure the tension portion diameter of the bolt.
Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)
If the diameter is less than the minimum, replace the connecting rod bolt.

17. INSPECT CRANKSHAFT BEARING CAP SET BOLT
(a) Using a vernier caliper, measure the tension portion diameter of the bolt.
Standard diameter: 10.0 to 10.2 mm (0.394 to 0.402 in.)
If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt.

18. INSPECT CYLINDER BLOCK FOR FLATNESS
(a) Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket.
Maximum warpage: 0.05 mm (0.00197 in.)
If the warpage is greater than the maximum, replace the cylinder block.

19. INSPECT CYLINDER BORE
(a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions.
Standard diameter: 94.000 to 94.012 mm (3.7008 to 3.7013 in.)
Maximum diameter: 94.132 mm (3.70 in.)
If the diameter is greater than the maximum, replace the cylinder block.

20. INSPECT PISTON WITH PIN SUB-ASSEMBLY
(a) Using a micrometer, measure the piston diameter at a right angle to the piston pin center line, 40.7 mm (1.60 in.) from the piston head.
Piston diameter: 93.950 to 93.960 mm (3.6988 to 3.6992 in.)
21. INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.060 to 0.102 mm (0.00236 to 0.00401 in.)
Maximum oil clearance: 0.13 mm (0.00512 in.)
If the oil clearance is greater than the maximum, replace all 6 pistons. If necessary, replace the cylinder block.

22. INSPECT PISTON PIN OIL CLEARANCE
(a) Check each mark on the piston, piston pin and connecting rod.

(b) Using a caliper gauge, measure the inside diameter of the piston pin hole.

Standard piston pin hole inside diameter:

Standard piston pin diameter:

(d) Using a caliper gauge, measure the inside diameter of the connecting rod bush.
Standard bush inside diameter

Standard Bush Inside Diameter:

(e) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement.
Standard oil clearance: 0.001 to 0.007 mm (0.0000394 to 0.000276 in.)
Maximum oil clearance: 0.040 mm (0.00157 in.)
If the oil clearance is greater than the maximum, replace the piston and piston pin as a set.
(f) Subtract the piston pin diameter measurement from the bush inside diameter measurement.
Standard oil clearance: 0.005 to 0.011 mm (0.000197 to 0.000433 in.)
Maximum oil clearance: 0.050 mm (0.00197 in.)
If the oil clearance is greater than the maximum, replace the bush. If necessary, replace the connecting rod and piston pin as a set.