Inspection

.
INSPECTION AND CLEANING OF COMPONENTS

1. CLEAN TOP OF PISTONS AND TOP OF BLOCK
(a) Turn the crankshaft and bring each piston to top dead center. Scrape the carbon from the piston top.
(b) Remove all gasket material from the top of the block. Blow carbon and oil from the bolt holes.
2. CLEAN COMBUSTION CHAMBERS

Using a wire brush, remove all the carbon from the combustion chambers.

CAUTION: Be careful not to scratch the head gasket contact surface.

3. CLEAN VALVE GUIDES

Using a valve guide brush and solvent, clean all the valve guides.
4. REMOVE GASKET MATERIAL

Using a gasket scraper, remove all gasket material from the manifold and head surface.

CAUTION: Do not scratch the surface.

5. CLEAN CYLINDER HEAD

Using a soft brush and solvent, clean the head.

CAUTION: Do not clean the head in a hot tank as this will seriously damage it.

6. CHECK HEAD FOR FLATNESS

(a) Using a precision straight edge and feeler gauge, check that neither the head nor manifold surface is warped.

(b) Measure warpage at the four sides and diagonally as illustrated.
Maximum head surface warpage: 0.10 mm (0.0039 in
Maximum intake manifold surface warpage: 0.10 mm (0.0039 in.)
Maximum exhaust manifold surface warpage: 0.10 mm (0.0039 in.)
Maximum camshaft housing surface warpage: 0.10 mm (0.0039 in.)
If warpage is greater than specified value, replace the head.
7. INSPECT CYLINDER HEAD FOR CRACKS

Using a dye penetrant, check the combustion chamber, intake and exhaust ports, head surface and the top of the head for cracks. If a crack is found, replace the head.
8. CLEAN VALVES

Use a gasket scraper to chip any carbon from the valve head. Using a wire brush, clean the valve thoroughly.
9. INSPECT VALVE STEM GUIDE WEAR

(a) Using a dial indicator or telescoping gauge, measure the inside diameter of the valve guide.
Standard inside diameter: 8.01 -8.03 mm (0.3154 - 0.3161 in.)

(b) Using a micrometer, measure the diameter of the valve stem.
Standard valve stem diameter:
Intake 7.970 - 7.985 mm (0.3138 - 0.3144)
Exhaust 7.965 - 7.980 mm (0.3136 - 0.3142)
(c) Subtract the valve stem measurement from the valve guide measurement.
Standard oil clearance:
Intake 0.025 - 0.060 mm (0.0010 - 0.0024 in.)
Exhaust 0.030 - 0.065 mm (0.0012 - 0.0026 in.)
Maximum oil clearance:
Intake 0.08 mm (0.0031 in.)
Exhaust 0.10 mm (0.0039 in.)
If the clearance is greater than following values, replace the valve and guide.
10. IF NECESSARY, REPLACE VALVE GUIDE

(a) Using a brass bar and hammer, break off the valve guide.
(b) Heat the cylinder head to approx. 90°C (194°F).

(d) Using a caliper gauge, measure the valve guide bore of the cylinder head

(e) Select a new valve guide.
If the valve guide bore of the cylinder head is more than 13.027 mm (0.5129 in.), machine the bore to the following dimensions. Rebored valve guide bushing bore dimension (cold) 13.05- 13.077 mm (0.5138 - 0.5148 in.)
(f) Heat the cylinder head to approx. 90°C (194°F)

(g) Using SST and a hammer, drive in the new valve guide until the snap ring makes contact with the cylinder head. SST 09201-60011

(h) Using a sharp 8 mm reamer, ream the valve guide to obtain specified clearance between the guide and new valve.
Standard oil clearance:
Intake 0.025 - 0.060 mm (0.0010 - 0.0024 in.)
Exhaust 0.030 - 0.065 mm (0.0012 - 0.0026 in.)
11. INSPECT AND GRIND VALVES
(a) Grind valves only enough to remove pits and carbon.

Make sure the valves are ground at the correct valve face angle. Valve face angle: 44-5O°

(b) Check the valve head margin.
Minimum margin: Intake 0.5 mm (0.020 in.) Exhaust 1.0 mm (0.039 in.)
If the valve head margin is less than specified, replace the valve.

(c) Check the surface of the valve stem tip for wear. Standard overall length:
Intake 107.5 mm (4.232 in.)
Exhaust 109.7 mm (4.319 in.)
If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.

CAUTION: Do not grind more than 0.5 mm (0.020 in.)

12. INSPECT AND CLEAN VALVE SEATS

(a) Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a thin coat of prussian blue (or white lead) to the valve face. Install the valve. While applying light pressure to the valve, rotate the valve against the seat.

(c) Check the valve face and seat for the following:
- If blue appears 360° around the face, the valve is concentric. If not, replace the valve.
- If blue appears 360° around the valve seat, the guide and seat are concentric. If not, resurface the seat.
- Check that the seat contact is on the middle of the valve face with the following width: 1.2 - 1.6 mm (0.047 - 0.063 in.) If not correct the valve seat as follows: If seating is too high on the valve face, use 30° and 45° cutters to correct the seat. If seating is too low on the valve face, use 60° (IN) or 67.50 (EX) and 45° cutters to correct the seat

(d) Hand-lap the valve and valve seat together with abrasive compound.
(e) Clean the valve and valve seat after hand-lapping.
13. INSPECT VALVE SPRINGS

(a) Using a steel square, check the squareness of the valve springs.
Maximum allowable: 2.0 mm (0.079 in.)
If squareness is greater than maximum, replace the valve spring.

(b) Measure the free height of all springs.
Free height:
Intake side 49.1 mm (1.933 in.)
Exhaust side 52.5 mm (2.067 in.)
Replace any spring that is not correct.

(c) Using a spring tester, check the tension of each spring at the specified installed height.
Installed height:
Intake side 40.0 mm (1.575 in.)
Exhaust side 43.0 mm (1.693 in.)
Installed tension:
Intake side 34.7 - 38.3 kg (76.5 - 84.4 lb, 340 - 376 N)
Exhaust side 33.3 - 36.7 kg (73.4 - 80.9 lb, 327 - 360 N)
If not within the installed tension specification, replace the spring.
14. INSPECT INTAKE, EXHAUST MANIFOLDS AND AIR INTAKE CHAMBER

Using a precision straight edge and feeler gauge, check the surfaces contacting the cylinder head for warpage.
Maximum intake warpage: 0.1 mm (0.004 in.)
Maximum exhaust warpage: 0.75 mm (0.0295 in.)
Maximum air intake chamber warpage: 0.1 mm (0.004 in.)
If warpage is greater than maximum, replace the manifold or air intake chamber.