Hi Kawboy, just a few things to go over !
I have removed the head, Inlet valve bent. Exhaust was also leaking so i will replace this one also. I have no idea how this has happened, I took utmost care when doing this.
Ok the head gasket looks good, you also mentioned gasket sealant ? I have not used any sealant, should I be using any ?
If you're using the original OEM head gasket which has sealant around the water jacket ports and oil ports then you could install the gasket dry. That being said, it wouldn't hurt to use a light coating of an appropriate head gasket sealer.
Could this problem be caused by slack in the cam chain, or a stretched chain ? If so when installing the cams where should I take the slack out of the cam chain. Would this be the exhaust cam side or the inlet side ?
You're experience here has probably got you gun shy, so let's dive in just a bit.
As per the manual, the first thing to do is install the exhaust cam. When doing this. at this point, all the inlet valves are seated so nothing bad can happen yet. Install the exhaust cam and torque down the cam bearing caps.
Now time the exhaust cam. Ensure the crankshaft is located with the "T" mark at the front crankcase cover. Pull the cam chain up at the front and engage the chain with the cam ensuring the timing mark on the camshaft is located at the half joint cylinder head cover. At this point the exhaust cam is completely installed and timed.
Next the manual talks about placing the intake cam in position and timing it first before tightening down the cam bearing caps by counting the 17 links and engaging the timing chain with the intake cam. The manual also mentions that you will have to rotate the crankshaft clockwise just enough to set the intake camshaft in the bearing journals. Note that when rotating the crank clockwise, the exhaust cam will also rotate. During this part of the installation, the cam chain should be tight between the exhaust cam and the secondary shaft and tight between the intake and exhaust camshaft. All the slack should be at the rear of the engine which is where the cam chain tensioner takes care of the slack. Tighten down torque the intake cam bearing caps.
As you say, this problem is not mentioned in the official workshop manual !!!
In all fairness the manual does state NOTE: Do not allow the chain to loosen even for a moment during camshaft installation mentioned below. This is the critical point in camshaft chain II timing. Although they could have emphasized this better with bold text
would I be able to check for this problem before turning that rotor for the first time !
Again many thanks for your help on this situation I'm in.
Once you have the tensioner installed, you could rotate the crank clockwise maybe 10 to 20 degrees and look at the chain down near the tensioner and see if the chain is slack, then rotate the crank shaft counter clockwise and see if any slack is present at the front of the engine between the exhaust cam and the secondary sprocket. there shouldn't be any to speak of.
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