Inspection / Repair
CYLINDER HEAD
1. Measure the cylinder head for distortion in the six directions as shown.
Distortion: 0.10 mm (0.004 inch) max.
2. Inspect for the following and repair or replace as necessary.
1) Sunken of valve seals
2) Damaged warm up three way catalytic converter contact surfaces
3) Excessive camshaft oil clearance and end play
3. If the cylinder head distortion exceeds specification, grind the cylinder head surface.
Grinding: 0.15 mm (0.006 inch) max.
4. If the cylinder head height is not within specification, replace it.
Height:
(A): 145.89 - 145.9g mm (5.7437 - 5.7476 inch)
(B): 127.81 - 127.91 mm (5.0319 - 5.0358 inch)
3. Measure the intake manifold and warm up three way catalytic converter contact surfaces for distortion in the six directions as shown.
Distortion: 0.10 mm (0.004 inch) max.
4. If distortion exceeds specification, grind the surface or replace the cylinder head.
Grinding: 0.15 mm - (0.006 inch) max.
VALVE MECHANISM
Valve And Valve Guide
1. Measure the valve head margin thickness. Replace the valve if necessary.
Margin thickness:
Standard:
IN: 0.775 - 1.325 mm (0.306 - 0.052 inch) min.
EX: 1.355 - 1.905 mm (0.054 - 0.074 inch) min.
2. Measure the valve length. Replace the valve if necessary.
Length
Standard
IN: 107.66 - 108.46 mm (4.2386 - 4.2700 inch)
EX: 107.71 - 108.51 mm (4.2406 - 4.2720 inch)
3. Measure the valve stem diameter in X and Y directions at three points (A,B and C) as shown. Replace the valve if necessary.
Diameter
IN: 5.970 - 5.985 mm (0.2351 - 0.2356 inch)
EX: 5.965 - 5.980 mm (0.2349 - 0.2354 inch)
Minimum
IN: 5.920 mm (0.2331 inch)
EX: 5.915 mm (0.2329 inch)
4. Measure the valve guide inner diameter in X and Y directions at three points (A, B and C) as shown. Replace the guide if necessary.
Inner diameter: 6.01 - 6.03 mm (0 .2367 - 0.2374 inch)
5. Calculate the valve stem-to-valve guide clearance. Subtract the outer diameter of the valve stem from the inner diameter of the corresponding valve guide.
Clearance
IN: 0.025 - 0.060 mm (0.0010 - 0.0023 inch)
EX: 0.030 - 0.065 mm (0.0012 - 0.0025 inch)
Maximum: 0.20 mm (0.008 inch)
6. If the clearance exceeds the maximum, replace the valve and/or valve guide.
7. Measure the valve guide projection height (dimension (A). Replace the valve guide if necessary.
Height A
IN: 13.4 - 14.0 mm (0.528 - 0.551 inch)
EX: 11.9 - 12.5 mm (0.469 - 0.492 inch)
Replacement Of Valve Guide
NOTE: The intake and exhaust valve guides are different.
1. Remove the valve guide from the combustion chamber side by using the Special Service Tool (SST).
2. Assemble the SST so that depth L is as specified.
Depth L
IN: 13.4 - 14.0 mm (0.528 - 0.551 inch)
EX: 11.9 - 12.5 mm (0.469 - 0.492 inch)
3. Tighten the nut.
4. Tap the valve guide in from the side opposite the combustion chamber until the SST contacts the cylinder head.
5. Verify that the valve guide projection height (dimension) is within specification.
Height (dimension)
IN: 13.4 - 14.0 mm (0.528 - 0.551 inch)
EX: 11.9 - 12.5 mm (0.469 - 0.492 inch)
6. If not, repeat steps 1 - 4.
Valve seat
1. If necessary, resurface the valve seat by using a 45° valve seat cutter and/or resurface the valve face.
2. Apply a thin coat of Prussian blue to the valve face.
3. Check the valve seating by pressing the valve against the seat.
1) If blue does not appear 360° around the valve face, replace the valve.
2) If blue does not appear 360° around the valve seat, resurface the seat.
4. Measure the seat contact width.
Width: 0.8 - 1.4 mm (0.031 - 0.055 inch)
5. Verify that the valve seating position is at the center of the valve face.
1) If the seating position is too high, correct the valve seat using a 70° (INCH) or 75° (EX) cutter, and a 45° cutter.
2) If the seating position is too low, correct the valve seat using a 35° (INCH) or 25° (EX) cutter, and a 45° cutter.
6. Seat the valve to the valve seat by using lapping compound.
7. Check the sinking of the valve seat.
1) Measure the protruding length (dimension L) of the valve stem.
Dimension L: 43.4 mm (1.709 inch)
2) If L is as below, it can be used as it is.
43.4 - 43.9 mm (1.709 - 1.728)
3) If L is more than below, replace the cylinder head.
44.0 mm (1.732 inch)
Valve spring
1. Check the following pressure. Replace the valve spring if necessary.
Standard:
35.9 mm (1.413 inch) with a set load of 187 - 205 Nm (42 - 46 lbs.)
2. Measure the out-of-square of the spring. Replace the valve spring if necessary.
Out-of-square: 1.57 mm (0.062 inch) max.
CAMSHAFT
1. Visually inspect the helical gears and the friction gear.
2. If a problem is found with the helical gear, replace the camshaft assembly.
3. If a problem is found with the friction gear, replace the friction gear as follows.
1) Secure the camshaft cast hexagon in a vise protected with aluminum plates.
2) Loosen the locknut and remove the friction gear.
3) Align the matching marks and assemble the new friction gear.
Tightening torque:
69 - 78 Nm (51 - 57 ft. lbs.)
4. Set the No. 1 and No. 5 journals on V-blocks.
Measure the camshaft runout at the No.2 - No. 4 journals. Replace the camshaft if necessary.
Runout: 0.02 mm (0.0008 inch) max.
5. Measure the cam lobe height at two points (A and B) as shown. Replace the camshaft if necessary.
Height
Standard
IN: 43.635 mm (1.7179 inch)
EX: 42.847 mm (1.6869 inch)
6. Measure the journal diameters in X and Y directions at two points (A and B) as shown. Replace the camshaft if necessary.
Journal diameter:
Standard:
No.1:
25.940 - 25.960 mm (1.0213 - 1.0220 inch) (IN)
29.975 - 29.995 mm (1.1802- 1.1809 inch) (EX)
No.2, 3, 4:
25.910 - 25.930 mm (1.0201 - 1.0208 inch)
No.5 25.940 - 25.960 mm (1.0213 - 1.0220 inch)
Minimum:
No.1:
25.890 mm (1.0193 inch) (INCH)
29.925 mm (1.1781 inch) (EX)
No.2, 3, 4:
25.860 mm (1.0181 inch)
No.5:
25.890 mm (1.0193 inch)
7. Measure the camshaft oil clearance with the tappet and shim removed.
1) Install the camshafts so that the intake camshaft gear mark and exhaust camshaft gear mark align.
2) Position Plastigage atop each journal in the journal axial direction.
3) Do not rotate the camshaft when measuring the oil clearance.
4) Install the thrust caps.
5) Install the camshaft caps.
CAUTION: Remove the thrust caps only after removing all camshaft caps. Otherwise, the thrust caps can be damaged.
6) Loosen the camshaft cap bolts in five or six steps in the order shown.
7) Remove the camshaft caps.
8) Measure the oil clearance.
Oil clearance
No. 1, No. 5:
0.040 - 0.081 mm (0.0016 - 0.0031 inch)
No. 2 - No. 4:
0.070 - 0.111 mm (0.0028 - 0.0043 inch)
9) If the oil clearance exceeds the specification, replace the camshaft or the cylinder head.
8. Measure the camshaft end play. If it exceeds the specification, replace the camshaft or the cylinder head.
End play: 0.05 - 0.10 mm (0.0020 - 0.0039 inch)
TAPPET
1. Measure the tappet bore in X and Y directions at two points (A and B) as shown.
Diameter: 30.000 - 30.025 mm (1.1811 - 1.1820 inch)
2. Measure the tappet diameter in X and Y directions at two points (A and B) as shown.
Diameter: 29.959 - 29.975 mm (1.1795 - 1.1801 inch)
3. Calculate the clearance between the tappet diameter and the related tappet bore.
Clearance:
0.025 - 0.066 mm (0.00099 - 0.00259 inch)
4. If the clearance exceeds the specification, replace the tappet and/or cylinder head.
CYLINDER BLOCK
1. Using a straightedge, measure the cylinder block decks for distortion in six directions as shown.
Distortion: 0.15 mm (0.0059 inch) max.
2. If distortion exceeds the maximum, replace the cylinder block.
3. Measure the cylinder bore in X and Y directions at three points (A,B and C) as shown.
Cylinder bore
Base the boring diameter on the diameter of an oversize piston. All cylinders must be the same diameter.
Maximum: 0.15 mm (0.0059 inch)
1) If the cylinder bore exceeds the maximum, replace the cylinder block or rebore the cylinder to oversize.
2) If the difference between measurements -A and C exceeds the maximum taper, replace the cylinder block or rebore the cylinder to oversize.
Taper: 0.022 mm (0.0009 inch) max.
3) If the difference between measurements X and Y exceeds the maximum out-of -round, rebore the cylinder to oversize.
Out-of-round: 0.020 mm (0.0008 inch) max.
4. If the upper part of a cylinder wall shows uneven wear, remove the ridge with a ridge reamer.
OIL JET
1. Apply compressed air of 206 - 245 kPa (30 - 35 psi) to oil jet valve (A) and verify that air passes through oil jet valve (B). If not, replace the oil jet.
2. Check the oil jet nozzles for clogs. Replace the nozzle if necessary.
PISTON
1. Measure the diameter of each piston at a right angle 90° to the piston pin, 28.5 mm (1.12 inch) below the oil ring groove lower edge.
Piston diameter
2. Measure the piston-to-cylinder clearance.
Clearance: 0.010 - 0.038 mm (0.0004 - 0.0014 inch)
Maximum: 0.112 mm (0.0044 inch)
3. If the clearance exceeds the maximum, replace the piston or rebore the cylinders to fit oversize pistons.
4. If the piston is replaced, the piston rings must also be replaced.
PISTON AND PISTON RING
1. Measure the piston groove clearance around the entire circumference by using a new piston ring.
Clearance
Top: 0.035 - 0.065 mm (0.0014 - 0.0025 inch)
Second: 0.030 - 0.065 mm (0.0012 - 0.0025 inch)
Oil: 0.07 - 0.16 mm (0.0028 - 0.0062 inch)
Maximum: 0.15 mm (0.0059 inch)
2. If the clearance exceeds the maximum, replace the piston and piston ring.
3. Insert the piston ring into the-cylinder by hand and use the piston pin to push it to the bottom of the ring travel.
4. Measure each piston ring end gap by using a feeler gauge.
End gap
Top: 0.15 - 0.25 mm (0.0060 - 0.0098 inch)
Second: 0.25 - 0.35 mm (0.0099 - 0.0137 inch)
Oil: 0.20 - 0.70 mm (0.0079 - 0.0275 inch)
Maximum: 1.0 mm (0.0394)
5. If the clearance exceeds the maximum, replace the piston ring.
PISTON AND PISTON PIN
1. Measure the piston pin bore in X and Y directions at four points (A, B, C and D) as shown.
Diameter:
20.988 - 21.000 mm (0.8263 - 0.8267 inch)
2. Measure the piston pin diameter in X and Y directions at four points (A, B, C and D) as shown.
Diameter:
20.987 - 20.993 mm (0.8263 - 0.8264 inch)
3. Calculate the piston pin bore-to-piston pin clearance.
Clearance:
-0.005 - 0.013 mm (-0.0002 - 0.0005 inch)
4. If the clearance exceeds specification, replace the piston and/or piston pin.
CONNECTING ROD
1. Measure the connecting rod side clearance.
Side clearance:
0.178 - 0.330 mm (0.0071 - 0.129 inch)
Maximum: 0.40 mm (0.0157 inch)
If the clearance exceeds the maximum, replace the connecting rod and cap assembly.
2. Measure the connecting rod bearing oil clearances as follows.
1) Measure the oil clearance with the connecting rod in BDC position.
2) Do not rotate the crankshaft when measuring the oil clearances.
3) Position Plastigage atop the journals in the axial direction.
4) Remove any foreign material and oil from the lower connecting rod bearing and connecting rod cap.
5) Install the connecting rod bearing in the cap.
6) Apply clean engine oil to the threads and seat faces of the connecting rod cap bolts.
7) Install the connecting rod cap.
8) Tighten the connecting rod cap bolts.
9) Remove the connecting rod cap.
10) Measure the Plastigage at each journal at the widest point for the smallest clearance, and the narrowest point for the largest clearance.
Oil clearance: 0.023 - 0.043 mm (0.0010 - 0.0016 inch)
Maximum: 0.08 mm (0.0031 inch)
11) If the clearance exceeds the maximum, grind the crankshaft and install undersize bearings.
Crank pin journal diameter undersize
3. Measure the connecting rod small end bore.
Diameter:
21.003 - 21.014 mm (0.8269 - 0.8273 inch)
4. Calculate the small end bore to piston pin. Replace the connecting rod if necessary.
Clearance: 0.010 - 0.027 mm (0.0004 - 0.0010 inch)
If the connecting rod is replaced, the connecting rod cap and bolts must also be replaced because they are a matched set.
5. Measure the connecting rod bending. Replace the connecting rod if necessary.
Bend: 0.05 mm (0.002 inch) / 50 mm (1.9685 inch) max.
Length (Center to center):
137.80 - 137.90 mm (5.4252 - 5.4291 inch)
CRANKSHAFT
1. Measure the crankshaft end play.
End play: 0.080 - 0.282 mm (0.0032 - 0.0111 inch)
Maximum: 0.32 mm (0.0126 inch)
2. If the end play exceeds the maximum, grind the crankshaft and install oversize thrust bearings or replace the crankshaft and thrust bearing.
Journal width
3. Set the crankshaft No.1 and No.4 main journals on V blocks.
4. Measure the crankshaft runout at the No.2 and No.3 main journals. Replace the crankshaft if necessary.
Runout: 0.015 mm (0.0006 inch) max.
5. Measure journal diameter in X and Y directions at two points (A and B) as shown.
Main journal
Diameter:
61.938 - 61.955 mm (2.4385 - 2.4391 inch)
Out-of-round: 0.04 mm (0.0016 inch) max.
Crank pin journal
Diameter:
52.940 - 52.955 mm (2.0843 - 2.0848 inch)
Out-of-round: 0.03 mm (0.0012 inch) max.
6. If the diameter is less than the specification, replace the crankshaft or grind the journals to match undersize bearings.
7. Measure the main bearing oil clearances as described below.
Oil Clearance Inspection
1) Install the upper main bearings and upper thrust bearings.
NOTE: No.4 bearing is wider than other bearings.
2) Install the lower cylinder block along with the lower main bearings and thrust bearings.
3) Apply clean engine oil to the bolt threads and seat faces of the lower cylinder block bolts.
4) Tighten the bolts.
5) After tightening, measure the cylinder block No.1 - No.4 journal bore diameter.
6) Subtract the main journal diameter from the bore diameter.
7) If the oil clearance exceeds the maximum, replace the bearing or grind the crankshaft and install undersize main bearings.
Oil clearance: 0.037- 0.057 mm (0.0015 - 0.0022 inch)
Maximum: 0.064 mm (0.0025 inch)
Main journal diameter
Standard:
61.938 - 61.955 mm (2.4385 - 2.4391 inch)
0.25 mm (0.01 inch) U.S.:
61.688 - 61.705 mm (2.4287 - 2.4293 inch)
TIMING BELT AUTO TENSIONER
1. Measure the auto tensioner rod projection (A). Replace the auto tensioner if necessary.
Projection (A) (Free length):
14 - 16 mm (0.56 - 0.62 inch)
2. Check the auto tensioner for oil leakage. Replace the auto tensioner if necessary.