09900-22302:Plastigauge

NOTE:

Installcamshaftjournalholderstotheiroriginalpositions.(tJ'"3-94)

•Tightenthecamshaftjournalholderboltsevenlyanddiago•

nallytothespecifiedtorque.

C!]Camshaftjournalholderbolt:1ON·m(1.0kgf·m,7.0lb-ft)

NOTE:

Donotrotatethecamshaftwiththeplastigaugeinplace.

_-

•Removethecamshaftholders,andreadthewidthofthecom•

pressedplastigaugewithenvelopescale.

•Thismeasurementshouldbetakenatthewidestpart.

•Ifthecamshaftjournaloilclearancemeasuredexceedsthelimit,measuretheinsidediameterofthecamshaftjournalholderandoutsidediameterofthecamshaftjournal.

•Replacethecamshaftorthecylinderheaddependinguponwhichoneexceedsthespecification.

~Journalholderl.D.:

Standard:(IN&EX):24.012-24.025mm

(0.9454-0.9459in)

1filit109900-20602:Dialgauge(1/1000,1mm)

09900-22403:Smallboregauge{18-35mm)

BCamshaftjournal0.0.:

Standard(IN&EX):23.959-23.980mm

(0.9433-0.9441in)

irUl.i09900-20205:Micrometer(0-25mm)

_-

-

_ENGINE3·31

CAMSHAFTRUNOUT

•Measuretherunoutusingthedialgauge.

•Replacethecamshaftiftherunoutexceedsthelimit.

IMI09900-20606:Dialgauge(1/100mm)

09900-20701:Magneticstand

09900-21304:V-blockset(100mm)

~Camshaftrunout:

ServiceLimit(IN&EX):0.10mm(0.004in)

CAMSPROCKET

•Inspectthesprocketteethforwear.

•Iftheyareworn,replacethesprocket/camshaftassemblyandcamchainasaset.

CAMCHAINTENSIONADJUSTER

INSPECTION

•Removethecamchaintensionadjustercapbolt.

•Checkthatthepushrodslidessmoothlywhenreleasingstop•

per.

•Ifitdoesnotslidesmoothly,replacethecamchaintensionad•

justerwithanewone.

CAMCHAINTENSIONER

INSPECTION

•Checkthecontactingsurfaceofthecamchaintensioner.

•Ifitiswornordamaged,replaceitwithanewone.

CAMCHAINGUIDE

INSPECTION

•Checkthecontactingsurfacesofthecamchainguides.

•Iftheyarewornordamaged,replacethemwiththenewones.

CYLINDERHEADANDVALVE

VALVEANDVALVESPRINGDISASSEMBLY

•RemovethetappetsG}andshims~byfingersormagnetichand.

IACAUTIONI

_{Identifythepositionofeachremovedpart.}

•Usingspecialtools,compressthevalvespringsandremovethetwocotterhalves@fromvalvestem.

nML!09916-14510:Valvelifter

09916-14521:Valvelifterattachment(IN.)

09916-14530:Valvelifterattachment(EX.)

09916-84511:Tweezers

IACAUTIONI

Becarefulnottodamagethetappetslidingsurfacewiththespecialtool.

•Removethevalvespringretainer@)andvalvesprings~-

_{•Pulloutthevalvefromtheotherside.}

-

_..

•Removetheoilseal1Dandthespringseat(2).

IACAUTIONI

IDonotreusetheremovedoilseal.

•Removetheothervalvesinthesamemannerasdescribedpreviously.

CYLINDERHEADDISTORTION

•Decarbonizethecombustionchambers.

•Checkthegasketedsurfaceofthecylinderheadfordistortionwithastraightedgeandthicknessgauge,takingaclearancereadingatseveralplacesindicated.

•Ifthelargestreadingatanypositionofthestraightedgeex•

ceedsthelimit,replacethecylinderhead.

ITOOh09900-20803:Thicknessgauge

•Cylinderheaddistortion:

ServiceLimit:0.20mm(0.008in)

VALVESTEMRUNOUT

•SupportthevalveusingV-blocksandcheckitsrunoutusingthedialgaugeasshown.

•Iftherunoutexceedstheservicelimit,replacethevalve.

1£h09900-20606:Dialgauge(1/100mm)

09900-20701:Magneticstand

09900-21304:V-blockset(100mm)

~Valvestemrunout:

ServiceLimit:0.05mm(0.002in)

VALVEHEADRADIALRUNOUT

•Placethedialgaugeatarightangletothevalveheadfaceandmeasurethevalveheadradialrunout.

•Ifitmeasuresmorethantheservicelimit,replacethevalve.

1.fooh09900-20606:Dialgauge(1/1oomm)

09900-20701:Magneticstand

09900-21304:V-blockset(100mm)

gValveheadradialrunout:

ServiceLimit:0.03mm(0.001in)

VALVEFACEWEAR

•Visuallyinspecteachvalvefaceforwear.Replaceanyvalvewithanabnormallywornface.Thethicknessofthevalvefacedecreasesasthefacewears.Measurethevalveface(i).Ifitisoutofspecification,replacethevalvewithanewone.

!r'&li09900-20102:Verniercalipers

~Valveheadthickness\'.t:

ServiceLimit:0.5mm(0.02in)

VALVESTEMDEFLECTION

•Liftthevalveabout1Omm(0.39in)fromthevalveseat.

•Measurethevalvestemdeflectionintwodirections,perpen•

diculartoeachother,bypositioningthedialgaugeasshown.

•Ifthedeflectionmeasuredexceedsthelimit,thendeterminewhetherthevalveortheguideshouldbereplacedwithanewone.

1.fui?t109900-20606:Dialgauge(1/100mm)

09900-20701:Magneticstand

6 Valvestemdeflection(IN&EX):ServiceLimit:0.35mm(0.014in)

VALVESTEMWEAR

•Itthevalvestemisworndowntothelimit,asmeasuredwithamicrometer,replacethevalve.

•Ifthestemiswithinthelimit,thenreplacetheguide.

•Afterreplacingvalveorguide,besuretorecheckthedeflec•

tion.

!TMI09900-20205:Micrometer(0-25mm)

gValvestemO.D.:

Standard(IN):3.975-3.990mm(0.1565-0.1571in)(EX):3.955-3.970mm(0.1557-0.1563in)

NOTE:

Ifvalveguideshavetoberemovedforreplacementafterinspect•ingrelatedparts,carryoutthestepsshowninvalveguideservic•ing.(Cr3-35)

VALVEGUIDESERVICING

•Usingthevalveguideremover,drivethevalveguideoutto•

wardtheintakeorexhaustcamshaftside.

!T'OOL!09916-53310:Valveguideremover/installer

NOTE:

*Discardtheremovedvalveguidesubassemblies.

*Onlyoversizedvalveguidesareavailableasreplacementparts.(PartNo.11115-11070)

•Re-finishthevalveguideholesincylinderheadwiththereamerandhandle.

1ro0t109916-49030:Valveguidereamer