Camshaft Journal, Camshaft Cap Clearance

Standard: 0.028 ~ 0.071 mm (0.0011 ~ 0.0028 in.)

Service Limit: 0.16 mm (0.0063 in.)

If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer.

Camshaft Journal Diameter

Standard: 23.950 ~ 23.972 mm (0.9429 ~ 0.9438 in.)

Service Limit: 23.92 mm (0.942 in.)

If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again.

If the clearance still remains out of the limit, replace the cylinder head unit.

 

 

Camshaft Runout

• Remove the camshaft (see Camshaft Removal).

• Set the camshaft in a camshaft alignment jig or on V

blocks.

• Measure runout with a dial gauge at the specified place as shown.

If the runout exceeds the service limit, replace the shaft.

Camshaft Runout

Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.1 mm (0.004 in.)

Cam Wear

• Remove the camshaft (see Camshaft Removal).

• Measure the height [A] of each cam with a micrometer.

If the cams are worn down past the service limit, replace

the camshaft.

Cam Height Standard:

Exhaust 35.843 ~ 35.957 mm (1.4111 ~ 1.4156 in.)

Inlet 36.543 ~ 36.657 mm (1.4387 ~ 1.4432 in.)

Service Limit:

Exhaust 35.74 mm (1.4071 in.)

Inlet 36.44 mm (1.4346 in.)

Camshaft Chain Removal

• Split the crankcase (see Crankcase Splitting in the Crank- shaft/Transmission chapter).

• Remove the camshaft chain [A] from the crankshaft

sprocket.

 

Cylinder Compression Measurement

NOTE

○Use the battery which is fully charged.

• Warm up the engine thoroughly.

• Stop the engine.

• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)

Stick Coils (see Stick Coil (Ignition Coil together with Spark Plug Cap) Removal in the Electrical System chap- ter)

Spark Plugs (see Spark Plug Replacement in the Peri- odic Maintenance chapter)

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132

NOTE

○Reconnect the connectors of the air switching valve

lead and the inlet air temperature sensor lead. When

the ignition switch is turned ON with the above connec- tors disconnected, the service codes (13, 64) are stores in the ECU.

• Attach the compression gauge [A] and adapter [B] firmly into the spark plug hole.

○Using the starter motor, turn the engine over with the throt-

tle fully open until the compression gauge stops rising; the

compression is the highest reading obtainable.

Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221 Compression Gauge Adapter, M10 × 1.0:

57001-1317

Cylinder Compression

Usable Range: 961 ~ 1 471 kPa (9.8 ~ 15.0 kgf/cm², 139

~ 213 psi) at 400 r/min (rpm)

• Repeat the measurement for the other cylinders.

• Install the spark plugs.

Torque - Spark Plugs: 15 N·m (1.5 kgf·m, 11 ft·lb)

 

○The following table should be consulted if the obtainable compression reading is not within the us- able range.

 

Problem	Diagnosis	Remedy (Action)
Cylinder compression is higher than usable range	Carbon accumulation on piston and in combustion chamber possibly due to damaged valve stem oil seal and/or damaged piston oil rings (This may be indicated by white exhaust smoke).	Remove the carbon deposits and replace damaged parts if necessary.
Incorrect cylinder head gasket thickness	Replace the gasket with a standard part.
Cylinder compression is lower than usable range	Gas leakage around cylinder head	Replace damaged gasket and check cylinder head warp.
Bad condition of valve seating	Repair if necessary.
Incorrect valve clearance	Adjust the valve clearance.
Incorrect piston/cylinder clearance	Replace the piston and/or cylinder.
Piston seizure	Inspect the cylinder and replace/repair the cylinder and/or piston as necessary.
Bad condition of piston ring and/or piston ring grooves	Replace the piston and/or the piston rings.

 

Cylinder Head Removal

• Remove:

Exhaust Pipes (see Exhaust Pipe Removal)

Cylinder Head Cover (see Cylinder Head Cover Re- moval)

Camshafts (see Camshaft Removal)

Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter)

Throttle Body Holder Water Hose

Water Temperature Sensor Connector Front Camshaft Chain Guide

 

 

• Firstly remove the M6 cylinder head bolts and M6 cylinder bolts [A].

• Secondly, remove the M8 bolts [B].

• Thirdly, remove the M10 nut [C].

• Fourthly, remove the M10 bolts [D].

 

 

Cylinder Head Installation

NOTE

○The camshaft cap is machined with the cylinder head,

so if a new cylinder head is installed, use the cap that

is supplied with the new head.

• Install a new cylinder head gasket [A] and dowel pins [B].

 

 

• Apply molybdenum disulfide oil solution [A] to both sides of washers and the threads of bolts and nut.

M10 Cylinder Head Bolts [B] M10 Cylinder Nut [C]

M8 Cylinder Bolt [D]

• Tighten the all the bolts and nut following the tightening sequence [1 ~ 8].

Torque - Cylinder Head Bolts (M10): First: 25 N·m (2.5 kgf·m, 18 ft·lb) Final:

Used Bolts 49 N·m (5.0 kgf·m, 36 ft·lb)

New Bolts 54 N·m (5.5 kgf·m, 40 ft·lb)

Cylinder Nut (M10): 49 N·m (5.0 kgf·m, 36 ft·lb)

Cylinder Bolt (M8): 27.5 N·m (2.8 kgf·m, 20 ft·lb)

NOTE

○The tightening sequence No.1 ~ No.5 are the cylinder

head bolts that are tightened between the cylinder head

with the crankcase.

○The No.6 is the cylinder head bolt that is tightened be-

tween the cylinder head with the cylinder.

○The No.7 and No.8 are the cylinder nut and cylinder

bolt that are tightened between the cylinder and the

crankcase.

 

 

• Tighten the M6 cylinder head bolts and M6 cylinder bolts [A].

Torque - Cylinder Head Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb)

Cylinder Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb)

• Install the front camshaft chain guide [A].

○Insert the end [B] of front camshaft chain guide into the

hollow on the lower crankcase half.

• Install the removed parts (see appropriate chapters).

 

Cylinder Head Warp

• Clean the cylinder head.

• Lay a straightedge across the lower surface of the cylinder

head at several positions.

• Use a thickness gauge [A] to measure the space between the straightedge [B] and the head.

Cylinder Head Warp Standard: – – –