Part Two

Cylinder Head Inspection for Warpage

36. Crankshaft Pulley






1. Hold the pulley with the holder handle (A) and the crankshaft pulley holder (B).

2. Remove the bolt with a socket, 19 mm (C) and a breaker bar, then remove the crankshaft pulley.

37. Engine Jack Support (State Of A Low Vehicle)

1. Lift and support the engine with a jack and a wood block under the oil pan.

38. Upper Torque Rod






1. Remove the upper torque rod.

39. Side Engine Mount






1. Remove the ground cable (A), the side engine mount bracket (B), and the side engine mount (C).

40. Side Engine Mount Bracket, Engine Side






1. Remove the side engine mount bracket.

41. Cam Chain Case






1. Remove the cam chain case (A) and the spacer (B).

42. Cam Chain Auto-Tensioner






1. Loosely install the crankshaft pulley.

2. Turn the crankshaft counterclockwise to compress the auto-tensioner.






3. Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the auto-tensioner (B), then insert a 1.2 mm (3/64 in) diameter pin (C) into the holes. Turn the crankshaft clockwise to secure the pin.

NOTE: If the holes in the lock and the auto-tensioner do not align, continue to rotating the crankshaft counterclockwise until the holes align, then install the pin.






4. Remove the auto-tensioner.

43. Cam Chain Tensioner Arm and Cam Chain Guide






1. Remove cam chain guide B.






2. Remove cam chain guide A and the tensioner arm (B).

44. Cam Chain

1. Remove the cam chain.

45. Camshaft Holder






1. Loosen the rocker arm and the adjusting screws (A).






2. Remove the camshaft holder bolts. To prevent damaging the camshafts, loosen the bolts, in sequence, two turns at a time.






3. Remove cam chain guide B , the camshaft holders (A).

46. Camshaft






1. Remove the camshafts (A).

47. Rocker Arm Assembly






1. Insert the bolts (A) into the rocker shaft holder, then remove the rocker arm assembly (B).

48. Cylinder Head Assembly






1. Remove the cylinder head bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.

2. Remove the cylinder head.

49. Rocker Arm Assembly - Disassembly

NOTE:
* Identify parts as they are removed so they can be reinstalled in their original locations.
* Inspect the rocker arm shaft and rocker arms.
* If reused, the rocker arms must be installed in their original location.
* When removing, or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders and the rocker arms on the shaft.
* Bundle the intake rocker arms with rubber bands to keep them together as a set, and remove the bands after the intake rocker arms have been installed.
* When replacing the intake rocker arm assembly, remove the fastening hardware from the new intake rocker arm assembly.





Inspection

1. Camshaft - Inspection






1. Put the rocker shaft holders, the camshaft, and the camshaft holders on the cylinder head, then tighten the bolts, in sequence, to the specified torque.

NOTE: If the engine does not have bolt (21), skip it and continue the torque sequence.






2. Seat the camshaft by pushing it away from the camshaft pulley end of the cylinder head.

3. Zero the dial indicator against the end of the camshaft, then push the camshaft back and forth, and read the end play. If the end play is beyond the service limit, replace the cylinder head and recheck. If it is still beyond the service limit, replace the camshaft.










4. Loosen the camshaft holder bolts two turns at a time, in a crisscross pattern. Then remove the camshaft holders from the cylinder head.

5. Lift the camshafts out of the cylinder head, and wipe them clean, then inspect the lift ramps. Replace the camshaft if any lobes are pitted, scored, or excessively worn.

6. Clean the camshaft journal surfaces in the cylinder head, then set the camshafts back in place. Place a plastigage strip across each journal.

7. Install the camshaft holders, then tighten the bolts to the specified torque as shown in step 1.

8. Remove the camshaft holders. Measure the widest portion of plastigage on each journal:

* If the camshaft-to-holder clearance is within the service limits, go to step 10.
* If the camshaft-to-holder clearance is beyond the service limit, and the camshaft has been replaced, replace the cylinder head.
* If the camshaft-to-holder clearance is beyond the service limit, and the camshaft has not been replaced, go to step 9.














9. Check the total runout with the camshaft supported on V-blocks:

* If the total runout of the camshaft is within the standard, replace the cylinder head.
* If the total runout is beyond the standard, replace the camshaft and recheck the camshaft-to-holder oil clearance. If the oil clearance is still beyond the standard, replace the cylinder head.






10. Measure cam lobe height.