Part 2

DISASSEMBLY
10. INSPECT CAMSHAFTS





a. Inspect for runout.
1) Place the camshaft on the 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. Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.





Cam lobe height

If the height is less than the minimum, replace the camshaft.





c. Inspect the camshaft journals.
Using a micrometer, measure the journal diameter.





Journal diameter

If the journal diameter is not as specified, check the oil clearance.
d. Inspect the journal clearance.
1) Clean the bearings, bearing caps and camshaft journals.
2) Install the bearings (See step 7).
3) Place the camshafts on the cylinder head.





4) Lay a strip of Plastigage across each of the camshaft journal.





5) Install the bearing caps.
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 bearing and/or camshaft. If necessary, replace the bearing caps and cylinder head as a set.





HINT: If using a standard bearing, replace it with one having the same number mark.





Reference
Cylinder head journal bore diameter





Standard bearing center wall thickness

Camshaft journal diameter: 35.971 - 35.985 mm (1.4165 - 1.4167 inch)
8) Remove the Plastigage completely.
9) Remove the camshafts.
10) Remove the bearings.





e. Inspect the thrust clearance.
1) Install the bearings.
2) Install the camshafts.
3) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.





Standard thrust clearance





Maximum thrust clearance

If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
4) Remove the bearings.
5) Remove the camshafts.





11. INSPECT VVT TIMING SPROCKET (VALVE TIMING CONTROLLER ASSEMBLY)
a. Apply vinyl tape to all the ports except the one.
b. Install the VVT timing sprocket.
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)

NOTICE: Do not push VVT timing sprocket to the camshaft forcibly when Installing it.

c. Check that the VVT timing sprocket will not turn.
d. Wind tape around the tip of the air gun and apply air of approximately 100 kPa (1 kgf/cm2, 14 psi) to the port of the cam shaft.

NOTICE: When the oil splashes, wipe it off with a shop rag and the likes.

HINT: Perform this in order to release the lock pin for the maximum delay angle locking.

e. Under the condition of (d), turn the VVT timing sprocket to the advance angel side (the arrow marked direction in the illustration) with your hand.
Standard: Must turn

HINT: Depending on the air pressure, the VVT timing sprocket will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released.

f. Except the position where the lock pin meets at the maximum delay angle, let the VVT timing sprocket turn back and forth and check the movable range and that there is no disturbance.
Standard: Movable smoothly in the range about 30°
g. Turn the VVT timing sprocket with your hand and lock it at the maximum delay angel position.
12. INSPECT VALVE LIFTERS AND LIFTER BORES





a. Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
Lifter bore diameter: 31.009 - 31.025 mm (1.2208 - 1.2215 inch)





b. Using a micrometer, measure the lifter diameter.
Lifter diameter: 30.966 - 30.976 mm (1.2191 - 1.2195 inch)
c. Subtract the lifter diameter measurement from the lifter bore diameter measurement.
Standard oil clearance: 0.033 - 0.059 mm (0.0013 - 0.0023 inch)
Maximum oil clearance: 0.079 mm (0.0031 inch)
If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head.





13. INSPECT EXHAUST MANIFOLD
Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 1.5 mm (0.0590 inch)
If warpage is greater than maximum, replace the exhaust manifold.





14. INSPECT CYLINDER HEAD BOLTS
Standard nominal length: 161.3 - 162.7 mm (6.350 - 6.405 inch)
Maximum nominal length: 164.2 mm (6.4646 inch)
If the length is greater than maximum, replace the bolt.