2. Start the engine and warm up to normal operating temperature until the electric cooling fan turns on.
3. Accelerate the engine for two minutes to 2500 rpm, check the noise of the pushers. If the noise remains, after stopping the engine, continue as follows.
4. Remove the valve cover, then rotate the crankshaft until the cam of the tappet to be checked is pointing straight up.
5. Using a non-metal tool, press the plunger down. If the free play is more than 0.1 mm before the valve starts to open, the tappet must be replaced as follows.
6. Remove the air filter or fuel injection system parts as described in Section 3.
7. Unscrew the nuts, remove the fuel container and hanger from the valve cover (where equipped).
8. Remove the toothed drive belt as described in Chapter 10. Do not remove the tensioner or sprockets from the intermediate shaft and crankshaft.
9. Turn off nuts, remove a back top covering of a gear belt of a drive from a valvate cover.
10. Loosen the remaining valve cover nuts, noting the location of the wiring harness and ground clamp. Disconnect the crankcase ventilation hose.
11. Remove reinforcement strips, lift valve cover.
12. Remove the oil deflector.
13. Remove a lining from racks on a head of the block of cylinders.
14. Remove the semicircular gasket from the groove in the front camshaft bearing cap. Also remove the rubber plug on the back of the cylinder head.
15. Use a screwdriver to remove the front camshaft oil seal.
16. Mark the position and orientation of the camshaft bearing caps, then loosen the nuts evenly and remove the caps.
17. Lift the camshaft off the cylinder head.
18. To fold the pushers, prepare a box with internal compartments numbered from the front end of the engine.
19. Remove the hydraulic tappets, place them upside down in the box to prevent oil from escaping.
20. Clean the camshaft (photo), check its condition on the lobes of the cams and on the bearing journals. Prepare a new seal.
21. Start assembly by lubricating the hydraulic tappets and placing them in the pre-marked positions on the valves.
22. Lubricate the bearing journals on the camshaft, then lower the camshaft into place on the pushrods with the lobes for cylinder #1 up.
23. Install bearing caps No. 2 and 5 (position no. 4 muted). Install the nuts and tighten them evenly with the tightening force specified in the Specification. Make sure the covers are properly oriented as noted when removed because they are slightly offset.
24. Install bearing caps No. 1 and 3, install nuts and tighten evenly with the tightening torque specified in the Specification.
25. Lubricate the tabs and outer rim of the new oil seal. Position it at the front end of the camshaft and hammer it into place with a socket and a mallet to the level of the cylinder head.
26. Install a new rubber plug and semi-circular gasket on the head and front bearing caps, then position the new gasket on the uprights.
27. Install oil deflector, valve cover and related parts. Tighten nuts.
28. Install the toothed drive belt as described in Chapter 10.
29. Install the seam container and hanger on the valve cover (if available).
30. Install the air filter or fuel injection parts as described in Section 3.
31. If any hydraulic tappets have been replaced, do not start or crank the engine for at least the next thirty minutes. This time is necessary for excess oil to flow out of the tappet. If this precaution is not observed, there is a danger of the valve hitting the piston.
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