Camshaft, Tappet and Shim Inspection - Suzuki Jimny Workshop Manual
1D
Camshaft, Tappet and Shim Inspection
Intake Cam Timing Sprocket Assembly (With VVT)
Fit intake cam timing sprocket assembly to camshaft (2) and hold hexagonal section of camshaft by using spanner or the like.
Check if sprocket (1) is not turned by hand.
If moved, replace intake cam timing sprocket assembly.
Cam Wear
Using a micrometer, measure cam height “a”. If measured height underruns its limit, replace camshaft.
Cam height “a” (Without VVT)
| Standard | Limit | |
|---|---|---|
| Intake cam |
44.919 – 45.079 mm
(1.768 – 1.775 in.) |
44.80 mm
(1.764 in.) |
| Exhaust cam |
44.399 – 44.559 mm
(1.748 – 1.754 in.) |
44.28 mm
(1.743 in.) |
Cam height “a” (With VVT)
| Standard | Limit | |
|---|---|---|
| Intake cam |
44.929 – 45.089 mm
(1.769 – 1.775 in.) |
44.80 mm
(1.764 in.) |
| Exhaust cam |
44.399 – 44.559 mm
(1.748 – 1.754 in.) |
44.28 mm
(1.743 in.) |
Camshaft Runout
Set camshaft between two “V” blocks, and measure its runout by using a dial gauge.
If measured runout exceeds limit, replace camshaft.
Camshaft runout limit
0.10 mm (0.0039 in.)
Camshaft Journal Wear
Without VVT
Check camshaft journals and camshaft housings for pitting, scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder head with housing. Never replace cylinder head without replacing housings.
Check clearance by using gauging plastic. Checking procedure is as follows.
1)
Clean housings and camshaft journals.
2)
Remove all tappets with shims.
3)
Install camshafts to cylinder head.
4)
Place a piece of gauging plastic to full width of journal of camshaft (parallel to camshaft).
5)
Install camshaft housing.
6)
Tighten camshaft housing bolts in such order as indicated in the figure a little at a time till they are tightened to specified torque.
NOTE:
Do not rotate camshaft while gauging plastic is installed.
7)
Remove housing, and using scale (2) on gauging plastic envelop (1), measure gauging plastic width at its widest point.
If measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft journal. Replace camshaft or cylinder head assembly whichever the difference from specification is greater.
Camshaft journal clearance
| Standard | Limit |
|---|---|
|
0.045 – 0.087 mm
(0.0018 – 0.0034 in.) |
0.12 mm
(0.0047 in.) |
Camshaft journal diameter [A]
| Item | Standard |
|---|---|
| No.1 |
26.934 – 26.955 mm
(1.0604 – 1.0612 in.) |
| Others |
22.934 – 22.955 mm
(0.9030 – 0.9037 in.) |
Camshaft journal bearing bore [B]
| Item | Standard |
|---|---|
| No.1 |
27.000 – 27.021 mm
(1.0630 – 1.0638 in.) |
| Others |
23.000 – 23.021 mm
(0.9056 – 0.9063 in.) |
With VVT
Check camshaft journals and camshaft housings for pitting, scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder head with housing. Never replace cylinder head without replacing housings.
Check clearance by using gauging plastic. Checking procedure is as follows.
1)
Clean housings and camshaft journals.
2)
Remove all tappets with shims.
3)
Install camshaft bearings (1) to cylinder head and camshaft No.1 housing.
CAUTION:
Do not apply engine oil to camshaft bearing back.
Only a upper half bearing of intake camshaft bearing No.1 has some holes. Other bearings.
4)
Install camshafts to cylinder head.
5)
Place a piece of gauging plastic to full width of journal of camshaft (parallel to camshaft).
6)
Install camshaft housing.
7)
Tighten camshaft housing bolts in such order as indicated in figure a little at a time till they are tightened to specified torque.
NOTE:
Do not rotate camshaft while gauging plastic is installed.
8)
Remove housing, and using scale (2) on gauging plastic (1) envelop, measure gauging plastic width at its widest point.
Camshaft journal clearance
| Standard | Limit | |
|---|---|---|
| Intake side No.1 housing |
0.020 – 0.072 mm
(0.0008 – 0.0028 in.) |
0.10 mm
(0.0039 in.) |
| Others |
0.045 – 0.087 mm
(0.0018 – 0.0034 in.) |
0.12 mm
(0.0047 in.) |
If measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft journal.
Replace camshaft bearing, camshaft or cylinder head assembly whichever the difference from specification is greater.
Camshaft journal diameter [A]
| Item | Standard |
|---|---|
| Intake side No.1 housing |
26.940 – 26.955 mm
(1.0606 – 1.0612 in.) |
| Exhaust side No.1 housing |
26.934 – 26.955 mm
(1.0604 – 1.0612 in.) |
| Others |
22.934 – 22.955 mm
(0.9029 – 0.9037 in.) |
Camshaft journal bearing bore [B]
| Item | Standard |
|---|---|
| Intake side No.1 housing | — |
| Exhaust side No.1 housing |
27.000 – 27.021 mm
(1.0630 – 1.0638 in.) |
| Others |
23.000 – 23.021 mm
(0.9055 – 0.9063 in.) |
Wear of Tappet and Shim
Check tappet and shim for pitting, scratches, or damage.
If any malcondition is found, replace.
Measure cylinder head bore and tappet outside diameter to determine cylinder head-to-tappet clearance. If clearance exceeds limit, replace tappet or cylinder head.
Cylinder head to tappet clearance
Standard: 0.025 – 0.066 mm (0.0010 – 0.0026 in.)
Limit: 0.15 mm (0.0059 in.)
Tappet outside diameter [A]
Standard: 30.959 – 30.975 mm (1.2189 – 1.2195 in.)
Cylinder head tappet bore [B]
Standard: 31.000 – 31.025 mm (1.2205 – 1.2215 in.)