Page 3833 of 5135
A09543
SSTSST
A09541
A09540
Sharp 6 mm
Reamer 14±28
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
16. INSTALL INTAKE VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
Diameter: 10.985 ± 11.006 mm (0.4325 ± 0.4333 in.)
If the bushing bore diameter of the cylinder head is greater then
11.006 mm (0.4333 in.), machine the bushing bore to the di-
mension of 11.035 ± 11.056 mm (0.4344 ± 0.4353 in.).
HINT:
Bushing sizeBushing bore diameter
mm (in.)
Use STD10.985 ± 11.006
(0.4325 ± 0.4333)
Use O/S 0.0511.035 ± 11.056
(0.4344 ± 0.4353)
(b) Heat the cylinder head to 80 ± 100C. (176 ± 212F)
(c) Using SST and a hammer, top in a new guide bushing to
the specified protrusion height.
SST 09201±10000 (09201±01060), 09950±70010
(09951±07100)
Protrusion height:
10.05 ± 10.45 mm (0.3957 ± 0.4114 in.)
(d) Using a sharp 6 mm reamer, ream the guide bushing to
obtain the standard specified clearance between the
guide bushing and valve stem.
Standard oil clearance:
0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)
Page 3834 of 5135
A56676
A56677
SST
A56678
Sharp 6 mm
Reamer
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±29
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
17. INSTALL EXHAUST VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
Diameter: 10.985 ± 11.006 mm (0.4325 ± 0.4333 in.)
If the bushing bore diameter of the cylinder head is greater then
11.006 mm (0.4333 in.), machine the bushing bore to the di-
mension of 11.035 ± 11.056 mm (0.4344 ± 0.4353 in.).
HINT:
Bushing sizeBushing bore diameter
mm (in.)
Use STD10.985 ± 11.006
(0.4325 ± 0.4333)
Use O/S 0.0511.035 ± 11.056
(0.4344 ± 0.4353)
(b) Heat the cylinder head to 80 ± 100C. (176 ± 212F)
(c) Using SST and a hammer, tap in a new guide bushing to
the specified protrusion height.
SST 09201±10000 (09201±01060), 09950±70010
(09951±07100)
Protrusion height:
9.65 ± 10.05 mm (0.3799 ± 0.3957 in.)
(d) Using a sharp 6 mm reamer, ream the guide bushing to
obtain the standard specified clearance between the
guide bushing and valve stem.
Standard oil clearance:
0.035 ± 0.070 mm (0.0014 ± 0.0028 in.)
18. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve against the seat.
Page 3835 of 5135
A56053
Width
4525
Z03988
45
70
A57105Contacting Width
A09537
14±30
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(c) Check the valve face and seat according to the following
procedure.
(1) If blue appears 360 around the face, the valve is
concentric. If not, replace the valve.
(2) If blue appears 360 around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the
valve face with the following width.
Intake1.2 ± 1.6 mm (0.047 ± 0.063 in.)
Exhaust1.6 ± 2.0 mm (0.063 ± 0.079 in.)
19. REPAIR INTAKE VALVE SEATS
NOTICE:
Take off a cutter gradually to make smooth valve seats.
(a) If the seating is too high on the valve face, use 25 and
45 cutters to correct the seat.
(b) If the seating is too low on the valve face, use 70 and
45 cutters to correct the seat.
(c) Hand±lap the valve and valve seat with an abrasive com-
pound.
(d) Check the valve seating position.
SST 99999±60014
Page 3836 of 5135
4525
Z03988
45
65
A57106
A56679
EM2196
A09544
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±31
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
20. REPAIR EXHAUST VALVE SEATS
NOTICE:
Take off a cutter gradually to make smooth valve seats.
(a) If the seating is too high on the valve face, use 25 and
45 cutters to correct the seat.
(b) If the seating is too low on the valve face, use 65 and 45
cutters to correct the seat.
(c) Hand±lap the valve and valve seat with an abrasive com-
pound.
(d) Check the valve seating position.
21. INSPECT VALVE LIFTER
(a) Using a micrometer, measure the lifter diameter.
Lifter diameter:
27.975 ± 27.985 mm (1.1014 ± 1.1018 in.)
22. INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter diameter:
28.010 ± 28.031 mm (1.1028 ± 1.1036 in.)
(b) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
0.025 ± 0.056 mm (0.0010 ± 0.0022 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
Page 3837 of 5135
A09550
A09551
A09552
A09546
Plastigage
A09557
14±32
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
23. INSPECT CAMSHAFT
(a) Inspect the circle runout.
(1) Place the camshaft on V±blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater then maximum, replace the cam-
shaft.
(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake46.57 ± 46.67 mm (1.8335 ± 1.8374 in.)
Exhaust47.52 ± 47.62 mm (1.8709 ± 1.8748 in.)
Minimum cam lobe height:
Intake46.10 mm (1.8150 in.)
Exhaust47.05 mm (1.8524 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
(c) Using a micrometer, measure the journal diameter.
Journal diameter:
26.969 ± 26.985 mm (1.0618 ± 1.0624 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
24. INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the bearing caps and camshaft carrier.
(b) Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps, cam-
shaft carrier and cylinder head as a set.
(c) Place the camshaft carrier and camshafts on the cylinder
head.
(d) Lay a strip of Plastigage across each of the camshaft jour-
nals.
(e) Install the bearing caps.
Torque: 20 Nm (200 kgfcm, 15 ftlbf)
NOTICE:
Do not turn the camshaft.
(f) Remove the bearing caps.
Page 3838 of 5135
A09547
A09545
A09548
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±33
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(g) Measure the Plastigage at its widest point.
Standard oil clearance:
0.025 ± 0.062 mm (0.0010 ± 0.0024 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. if necessary, replace the bearing caps, camshaft carrier
and cylinder head as a set.
(h) Completely remove the Plastigage.
25. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshaft.
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.035 ± 0.110 mm (0.0014 ± 0.0043 in.)
If the thrust clearance is not as specified, replace the camshaft.
If necessary, replace the bearing caps, camshaft carrier and
cylinder head as a set.
26. INSPECT CAMSHAFT GEAR BACKLASH
(a) Install the camshafts.
(b) Using a dial indicator, measure the backlash.
Standard backlash:
0.014 ± 0.070 mm (0.0006 ± 0.0028 in.)
Maximum backlash: 0.17 mm (0.0067 in.)
If the backlash is greater then maximum, replace the cam-
shafts.
Page 3839 of 5135
A56680
Intake Side:Cylinder Block Side:
Front Side: Rear Side:
1.5 mm 14±34
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
27. INSTALL TIGHT PLUG
(a) Apply adhesive around tight plugs.
Adhesive: Part No.08833 ± 00070, THREE BOND 1324
or equivalent
(b) Using SST, tap in the tight plugs as shown in the illustra-
tion.
SST 09950±60010 (09951±00210), 09950±70010
(09951±07100)
Page 3840 of 5135
A56681
Intake Side: Upper Side:
Protrusion Height: 3 mm
11 m m8 mm
12.5 mm8 mmProtrusion Height: 3 mm
A56682
Upper Side:
11 m m Front Side:
16 mm
7 mm
7 mm
Protrusion Height: 11 mm Protrusion Height: 6 mm
± ENGINE MECHANICALCYLINDER HEAD ASSY (1CD±FTV)
14±35
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
28. INSTALL RING PIN
(a) Using a plastic±faced hammer, tap in new ring pins to the
specified protrusion height.
29. INSTALL STRAIGHT PIN
(a) Using a plastic±faced hammer, tap in the straight pin.