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Camshaft-to-Holder Oil Clearance
Standard (New):
No. 1 Journal: 0.030 0.069 mm
(0.001 0.003 in.)
No. 2, 3, 4, 5 Journals: 0.060 0.099 mm (0.002 0.004 in.)
Service Limit: 0.15 mm (0.006 in.) Camshaft Total Runout
Standard (New): 0.03 mm (0.001 in.) max.
Service Limit: 0.04 mm (0.002 in.)
Cam Lobe Height Standard (New):
6-51
INTAKE
SEC PRI
C/C
5. Loosen the camshaft holder bolts two turns at a time, in a crisscross pattern. Then remove the
camshaft holders from the cylinder head.
6. Lift the camshafts out of the cylinder head, wipe them clean, then inspect the lift ramps. Replace the
camshaft if any lobes are pitted, scored, or
excessively worn.
7. Clean the camshaft journal surfaces in the cylinder head, then set the camshafts back in place. Place a
plastigage strip across each journal.
8. Install the camshaft holders, then tighten the bolts to the specified torque as shown in step 2.
9. 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 11.
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 10. 10. Check the total runout with the camshaft supported
on V-blocks.
If the total runout of the camshaft is within the service limit, replace the cylinder head.
If the total runout is beyond the service limit, replace the camshaft, and recheck the camshaft-
to-holder oil clearance. If the oil clearance is still
beyond the service limit, replace the cylinder
head.
11. Measure the cam lobe height. INTAKE EXHAUST
PRI 34.263 mm (1.3489 in.) 34.092 mm
(1.3422 in.)
SEC 29.638 mm (1.1668 in.)
PRI: Primary SEC: Secondary C/C: Cam Chain
08/08/21 14:28:18 61SNR030_060_0051
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DYNOMITE -2009-
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Camshaft-to-Holder Oil Clearance
Standard (New):
No. 1 Journal: 0.030 0.069 mm
(0.001 0.003 in.)
No. 2, 3, 4, 5 Journals: 0.060 0.099 mm (0.002 0.004 in.)
Service Limit: 0.15 mm (0.006 in.) Camshaft Total Runout
Standard (New): 0.03 mm (0.001 in.) max.
Service Limit: 0.04 mm (0.002 in.)
Cam Lobe Height Standard (New):
6-53
INTAKE
EXHAUST
PRI MID SEC SEC
MID PRI
C/C C/C
5. Loosen the camshaft holder bolts two turns at a
time, in a crisscross pattern. Then remove the
camshaft holders from the cylinder head.
6. Lift the camshafts out of the cylinder head, wipe them clean, then inspect the lift ramps. Replace the
camshaft if any lobes are pitted, scored, or
excessively worn.
7. Clean the camshaft journal surfaces in the cylinder head, then set the camshafts back in place. Place a
plastigage strip across each journal.
8. Install the camshaft holders, then tighten the bolts to the specified torque as shown in step 2.
9. 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 11.
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 10. 10. Check the total runout with the camshaft supported
on V-blocks.
If the total runout of the camshaft is within the service limit, replace the cylinder head.
If the total runout is beyond the service limit, replace the camshaft and recheck the camshaft-
to-holder oil clearance. If the oil clearance is still
beyond the service limit, replace the cylinder
head.
11. Measure the cam lobe height. INTAKE EXHAUST
PRI 32.791 mm (1.2910 in.) 32.772 mm
(1.2902 in.)
MID 35.534 mm (1.3990 in.) 34.768 mm
(1.3688 in.)
SEC 32.678 mm (1.2865 in.) 32.661 mm
(1.2859 in.)
PRI: Primary MID: Mid SEC: Secondary
C/C: Cam Chain
08/08/21 14:28:19 61SNR030_060_0053
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DYNOMITE -2009-
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Valve Guide Installed Height
Intake: 15.2 16.2 mm (0.598 0.638 in.)
Exhaust: 15.5 16.5 mm (0.610 0.650 in.)
6-57
B
A
07742-0010100
07HAH-PJ70100
9. Apply a thin coat of new engine oil to the outside of
the new valve guide. Install the guide from the
camshaft side of the head, use the valve guide
driver to drive the guide in to the specified installed
height (A) of the guide (B). If you have all 16 guides
to do, you may have to reheat the head. 10. Coat both valve guide reamer, 5.5 mm and the
valve guide with cutting oil.
11. Rotate the reamer clockwise to the full length of the valve guide bore.
12. Continue to rotate the reamer clockwise while removing it from the bore.
13. Thoroughly wash the guide in detergent and water to remove any cutting residue.
14. Check the clearances with a valve (see page 6-55). Verify that a valve slides into the intake and
exhaust valve guides without sticking.
15. Inspect the valve seating, if necessary renew the valve seat using a valve seat cutter (see page 6-58).
08/08/21 14:28:22 61SNR030_060_0057
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Intake Valve Stem Installed Height
Standard (New): 44.0 44.5 mm (1.73 1.75 in.)
Service Limit: 44.7 mm (1.76 in.)
Exhaust Valve Stem Installed Height
Standard (New): 44.1 44.6 mm (1.74 1.76 in.)
Service Limit: 44.8 mm (1.76 in.) Special Tools Required
6-596-59
Valve, Spring, and Valve Seal
Installation
A
AB
07PAD-0010000
F
D
EC
8. Insert the intake and exhaust valves in the head, and measure the valve stem installed height (A).
9. If the valve stem installed height is beyond the service limit, replace the valve and recheck. If it is
still beyond the service limit, replace the cylinder
head, the valve seat in the head is too deep. Stem seal driver 07PAD-0010000
Valve spring compressor attachment 07757-PJ1010A
1. Coat the valve stems with new engine oil. Install the valves in the valve guides.
2. Check that the valves move up and down smoothly.
3. Install the spring seats on the cylinder head.
4. Install the new valve seals (A) using the 5.5 mm side of the stem seal driver (B).
NOTE: The exhaust valve seal (C) has a black spring
(D), and the intake valve seal (E) has a white spring
(F). They are not interchangeable.
(cont’d)
08/08/21 14:28:23 61SNR030_060_0059
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DYNOMITE -2009-
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Intake Valve Stem Installed Height
Standard (New): 44.0 44.5 mm (1.73 1.75 in.)
Service Limit: 44.7 mm (1.76 in.)
Exhaust Valve Stem Installed Height
Standard (New): 44.1 44.6 mm (1.74 1.76 in.)
Service Limit: 44.8 mm (1.76 in.) Special Tools Required
6-596-59
Valve, Spring, and Valve Seal
Installation
A
AB
07PAD-0010000
F
D
EC
8. Insert the intake and exhaust valves in the head, and measure the valve stem installed height (A).
9. If the valve stem installed height is beyond the service limit, replace the valve and recheck. If it is
still beyond the service limit, replace the cylinder
head, the valve seat in the head is too deep. Stem seal driver 07PAD-0010000
Valve spring compressor attachment 07757-PJ1010A
1. Coat the valve stems with new engine oil. Install the valves in the valve guides.
2. Check that the valves move up and down smoothly.
3. Install the spring seats on the cylinder head.
4. Install the new valve seals (A) using the 5.5 mm side of the stem seal driver (B).
NOTE: The exhaust valve seal (C) has a black spring
(D), and the intake valve seal (E) has a white spring
(F). They are not interchangeable.
(cont’d)
08/08/21 14:28:23 61SNR030_060_0059
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Connecting Rod End Play
Standard (New): 0.15 0.30 mm (0.006 0.012 in.)
Service Limit: 0.40 mm (0.016 in.) Crankshaft End Play
Standard (New): 0.10 0.35 mm (0.004 0.014 in.)
Service Limit: 0.45 mm (0.018 in.)
7-5
Connecting Rod and Crankshaft End Play Inspection
1. Remove the oil pump (see page 8-16).
2. Remove the baffle plates (see step 8 on page 7-13).
3. Measure the connecting rod end play with a feeler
gauge between the connecting rod and the
crankshaft.
4. If the connecting rod end play is beyond the service limit, install a new connecting rod, and recheck. If it
is still beyond the service limit; replace the
crankshaft (see page 7-13). 5. Push the crankshaft firmly away from the dial
indicator, and zero the dial against the end of the
crankshaft. Then pull the crankshaft firmly back
toward the indicator, the dial reading should not
exceed the service limit.
6. If the end play is beyond the service limit, replace the thrust washers and recheck. If it is still beyond
the service limit, replace the crankshaft (see page
7-13).
08/08/21 14:32:32 61SNR030_070_0005
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DYNOMITE -2009-
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Main Bearing Clearance Inspection
Main Bearing-to-Journal Oil Clearance
No.1,2,4,5Journals:
Standard (New): 0.017 0.041 mm (0.0007 0.0016 in.)
Service Limit: 0.050 mm (0.0020 in.)
No. 3 Journal:
Standard (New): 0.025 0.049 mm (0.0010 0.0019 in.)
Service Limit: 0.055 mm (0.0022 in.)
7-6 Engine Block
Crankshaft Main Bearing Replacement
1. To check the main bearing-to-journal oil clearance,
remove the lower block and the bearing halves
(see page 7-13).
2. Clean each main journal and bearing half with a clean shop towel.
3. Place one strip of plastigage across each main journal.
4. Reinstall the bearings and lower block, then tighten the bolts to 29 N·m (3.0 kgf·m, 22 lbf·ft) 56 ° in
thepropersequence(seestep19onpage7-27).
NOTE: Apply new engine oil to the bolt threads and flanges.
Do not rotate the crankshaft during inspection.
5. Remove the lower block and the bearings again, and measure the widest part of the plastigage. 6. If the plastigage measures too wide or too narrow,
remove the crankshaft, and remove the upper half
of the bearing. Install a new, complete bearing with
the appropriate color code(s), and recheck the
clearance. Do not file, shim, or scrape the bearings
or the caps to adjust clearance.
7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below the current one), and
check again. If the proper clearance cannot be
obtained by using the appropriate larger or smaller
bearings, replace the crankshaft, and start over.
08/08/21 14:32:32 61SNR030_070_0006
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DYNOMITE -2009-
Connecting Rod Bearing Selection
Connecting Rod Big End Bore Code LocationsNormal Bore Size
K20Z2 engine: 48.0 mm (1.89 in.)
K20Z3 engine: 51.0 mm (2.01 in.)
7-9
8. If the plastigage measures too wide or too narrow,remove the upper half of the bearing, install a new,
complete bearing with the appropriate color
code(s), and recheck the clearance. Do not file,
shim, or scrape the bearings or the caps to adjust
clearance.
9. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below the current one), and
check clearance again. If the proper clearance
cannot be obtained by using the appropriate larger
or smaller bearing, replace the crankshaft, and start
over. 1. Inspect each connecting rod for cracks and heat
damage.
2. Each rod has a tolerance range from 0 to 0.024 mm (0.0009 in.), in 0.006 mm (0.0002 in.) increments,
depending on the size of its big end bore. It is then
stamped with a number or bar (1, 2, 3, or 4/l, ll, lll,
or llll) indicating the range. You may find any
combination of numbers and bars in any engine.
(Half the number or bar is stamped on the bearing
cap, the other half is on the rod.)
If you cannot read the code because of an
accumulation of oil and varnish, do not scrub it
with a wire brush or scraper. Clean it only with
solvent or detergent.
(cont’d)
08/08/21 14:32:33 61SNR030_070_0009
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DYNOMITE -2009-