Part 2

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

Journal diameter:
Intake: 26.949 - 26.965 mm (1.0610 - 1.0616 inch)
Exhaust: 26.959 - 26.975 mm (1.0613 - 1.0620 inch)

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





17. Inspect camshaft bearings.
Check that bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set.





18. Inspect camshaft journal 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 journal.





d. Install the bearing caps.

Torque: 16 Nm (12 ft. lbs.)

NOTICE: Do not turn the camshaft.

e. Remove the bearing caps.





f. Measure the Plastigage at its widest point.

Standard oil clearance:
Intake: 0.035 - 0.072 mm (0.0014 - 0.0028 inch)
Exhaust: 0.025 - 0.062 mm (0.0010 - 0.0024 inch)
Maximum oil clearance:
Intake: 0.10 mm (0.0039 inch)
Exhaust: 0.09 mm (0.0035 inch)

If the oil clearance is greater than maximum, replace the cam shaft. If necessary, replace the bearing caps and cylinder head as a set.
g. Completely remove the Plastigage.
h. Remove the camshafts.





19. 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: 0.040 - 0.090 mm (0.0016 - 0.0035 inch)
Maximum thrust clearance: 0.12 mm (0.0047 inch)

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





20. Inspect camshaft gear backlash.
a. Install the camshafts without installing the exhaust cam shaft sub gear.
Using a dial indicator, measure the backlash.

Standard backlash: 0.020 - 0.200 mm (0.0008 - 0.0079 inch)
Maximum backlash: 0.30 mm (0.0188 inch)

If the backlash is greater then maximum, replace the camshafts.
c. Remove the camshafts.





21. Inspect camshaft gear spring.
Using vernier calipers, measure the free distance between the spring ends.

Free distance: 18.2 - 18.8 mm (0.712 - 0.740 inch)

If the free distance is not as specified, replace the gear spring.





22. Inspect valve lifters and lifter bores.
a. Using a caliper gauge, measure the lifter bore diameter of the cylinder head.

Lifter bore diameter: 31.000 - 31.018 mm (1.2205 - 1.2212 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: 0.024 - 0.050 mm (0.0009 - 0.0020 inch)
Maximum oil clearance: 0.07 mm (0.0028 inch)

If the oil clearance is greater than maximum, replace the lifter.
If necessary, replace the cylinder head.





23. Inspect air intake chamber.
Using a precision straight edge and feeler gauge, measure the surface contacting the intake manifold for warpage.

Maximum warpage: 0.10 mm (0.0039 inch)

If warpage is greater than maximum, replace the chamber.





24. Inspect intake manifold.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head and air intake chamber for warpage.

Maximum warpage:
Air intake chamber side: 0.15 mm (0.0059 inch)
Cylinder head side: 0.08 mm (0.0031 inch)

If warpage is greater than maximum, replace the manifold.





25. Inspect exhaust manifolds.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.

Maximum warpage: 0.50 mm (0.0196 inch)

If warpage is greater than maximum, replace the manifold.





26. Inspect 12 pointed head cylinder head bolts.
Using vernier calipers, measure the tension portion diameter of the bolt.

Standard outside diameter: 8.95 - 9.05 mm (0.3524 - 0.3563 inch)
Minimum outside diameter: 8.75 mm (0.3445 inch)

If the diameter is less than minimum, replace the bolt.





27. If necessary, replace spark plug tube gaskets.
a. Bend up the tab on the ventilation baffle plate which prevents the gasket from the slipping out.
b. Using a screwdriver and hammer, tap out the gasket.





c. Using needle-nose pliers, pry out the gasket.





d. Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.
SST 09608-03071
e. Apply a light coat of MP grease to the gasket lip.
f. Return the ventilation plate tab to its original position.


REASSEMBLY

HINT:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets and oil seals with new ones.





1. Install spark plug tubes.

HINT: When using a new cylinder head, spark plug tubes must be installed.

a. Apply adhesive to the end of the spark plug tube.

Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent





b. Using a press, press in a new spark plug tube until there is 42.4 - 43.4 mm (1.669 - 1.709 inch) protruding from the camshaft bearing cap installation surface of the cylinder head.

NOTICE: Avoid pressing a new spark plug tube in too far by measuring the amount of the protrusion while pressing.





2. Install PVC pipes.

HINT: When using a new cylinder head, PCV pipe must be installed. Using a wooden block and hammer, tap in a new PCV pipe until its top side is flush with the cylinder head edge.

NOTICE: Be careful not to damage the cylinder head edge.





3. Install valves.
a. Using SST, push in a new oil seal.
SST 09201-01020





HINT: The intake valve oil seal is light brown and the exhaust valve oil seal is gray.

NOTICE: Pay much attention when assembling the oil seal for intake and exhaust. Assembling the wrong one may cause a failure.





b. Install these parts:
1) Valve
2) Spring seat
3) Valve spring
4) Spring retainer





c. Using SST, compress the valve spring and place the 2 keepers around the valve stem.
SST 09202 - 70020 (09202-00010)





d. Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.
4. Install valve lifters and shims.
a. Install the valve lifter and shim.
b. Check that the valve lifter rotates smoothly by hand.


















DISASSEMBLY





1. Remove valve lifters and shims.

HINT: Arrange the valve lifters and shims in the correct order.





2. Remove valves.
a. Using SST, compress the valve spring and remove the 2 keepers.
SST 09202 - 70020 (09202 - 00010)
b. Remove these parts:
- Spring retainer
- Valve spring
- Valve





c. Using needle-nose pliers, remove the oil seal.





d. Using compressed air and a magnetic finger, remove the spring seat by blowing air.

HINT: Arrange the valves, valve springs, spring seats and spring retainers in the correct order.