CYLINDER HEAD INSPECTION


  1. CLEAN CYLINDER HEAD SUB-ASSEMBLY

    A01E1K3E01

    1. Clean the cylinder head.


      1. Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.

        Note

        Be careful not to scratch the cylinder block contact surface.

    2. A01E0EOE01

      Using a valve guide bushing brush and solvent, clean all the guide bushes.

    3. A01E2FME01

      Using a soft brush and solvent, thoroughly clean the cylinder head.

  2. INSPECT CYLINDER HEAD SUB-ASSEMBLY

    A01E2EJE01

    1. Inspect the cylinder head warpage.


      1. Using a precision straightedge and feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage.

        Maximum warpage
        0.15 mm (0.0059 in.)

        If the warpage is greater than the maximum, replace the cylinder head.

    2. A01E2H5E01

      Inspect the cylinder head for cracks.


      1. Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.

        If cracked, replace the cylinder head.

  3. CLEAN INTAKE VALVE

    A01E2IKE01

    1. Using a gasket scraper, chip off any carbon from the valve head.

    2. Using a wire brush, thoroughly clean the valve.

  4. INSPECT INTAKE VALVE

    A01DZJUE01

    1. Using a micrometer, measure the diameter of the valve stem.

      Standard valve stem diameter
      5.970 to 5.985 mm (0.2350 to 0.2356 in.)

      If the diameter is not as specified, replace the valve.

    2. A01DVCTE04

      Check the valve face angle.


      1. Grind the valve enough to remove pits and carbon.

      2. Check that the valve is ground to the correct valve face angle.

        Standard valve face angle
        44.5°

        If the valve is worm, replace the valve.

    3. A01E298E03

      Check the valve head margin thickness.

      Standard margin thickness
      1.1 mm (0.043 in.)
      Minimum margin thickness
      0.6 mm (0.024 in.)

      If the margin thickness is less than the minimum, replace the valve.

    4. A01DZW4E03

      Check the valve overall length.

      Standard overall length
      105.15 to 105.75 mm (4.1398 to 4.1634 in.)
      Minimum overall length
      104.65 mm (4.1201 in.)

      If the overall length is less than the minimum, replace the valve.

    5. A01E05QE01

      Check the surface of the valve stem tip for wear.

      If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.

      Note

      Do not grind off more than the minimum.

  5. CLEAN EXHAUST VALVE

    A01E2IKE01

    1. Using a gasket scraper, chip off any carbon from the valve head.

    2. Using a wire brush, thoroughly clean the valve.

  6. INSPECT EXHAUST VALVE

    A01DZJUE01

    1. Using a micrometer, measure the diameter of the valve stem.

      Standard valve stem diameter
      5.960 to 5.975 mm (0.2346 to 0.2352 in.)

      If the diameter is not as specified, replace the valve.

    2. A01DVCTE04

      Check the valve face angle.


      1. Grind the valve enough to remove pits and carbon.

      2. Check that the valve is ground to the correct valve face angle.

        Standard valve face angle
        44.5°

        If the valve face is worn, replace the valve.

    3. A01E298E03

      Check the valve head margin thickness.

      Standard margin thickness
      1.2 mm (0.047 in.)
      Minimum margin thickness
      0.7 mm (0.028 in.)

      If the margin thickness is less than the minimum, replace the valve.

    4. A01DZW4E03

      Check the valve overall length.

      Standard overall length
      105.02 to 105.62 mm (4.1347 to 4.1583 in.)
      Minimum overall length
      104.52 mm (4.1150 in.)

      If the overall length is less than the minimum, replace the valve.

    5. A01E05QE01

      Check the surface of the valve stem tip for wear.

      If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.

      Note

      Do not grind off more than minimum.

  7. INSPECT COMPRESSION SPRING

    A01E1GRE03

    1. Using a steel square, measure the deviation of the spring.

      Maximum deviation
      2.0 mm (0.079 in.)

      If the deviation is greater than the maximum, replace the spring.

    2. A01DX7OE01

      Using a vernier caliper, measure the free length of the spring.

      Standard free length
      Blue Mark None
      46.8 mm (1.843 in.) 46.5 mm (1.831 in.)

      If the free length is not as specified, replace the spring.

    3. A01E05JE01

      Using a spring tester, measure the tension of the valve spring at the specified installed length.

      Standard installed tension (at 33.1 mm (1.303 in.))
      Blue Mark None
      149.9 to 166.1 N (15.3 to 16.9 kgf, 33.7 to 37.3 lbf) 150.2 to 165.8 N (15.3 to 16.9 kgf, 33.7 to 37.3 lbf)

      If the tension is not as specified, replace the spring.

  8. INSPECT INTAKE VALVE GUIDE BUSH

    A01E00YE01

    1. Using a caliper gauge, measure the inside diameter of the guide bush.

      Standard bush inside diameter
      6.010 to 6.030 mm (0.2366 to 0.2374 in.)

      If the journal diameter is not as specified, check the oil clearance.

    2. Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.

      Standard oil clearance
      0.025 to 0.060 mm (0.0010 to 0.0024 in.)
      Maximum oil clearance
      0.08 mm (0.0031 in.)

      If the clearance is greater than the maximum, replace the valve and guide bush.

  9. INSPECT EXHAUST VALVE GUIDE BUSH

    A01E001E01

    1. Using a caliper gauge, measure the inside diameter of the guide bush.

      Standard bush inside diameter
      6.010 to 6.030 mm (0.2366 to 0.2374 in.)

      If the journal diameter is not as specified, check the oil clearance.

    2. Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.

      Standard oil clearance
      0.035 to 0.070 mm (0.0014 to 0.0028 in.)
      Maximum oil clearance
      0.10 mm (0.0039 in.)

      If the clearance is greater than the maximum, replace the valve and guide bush.

  10. INSPECT INTAKE VALVE SEAT

    A01DZ9HE02

    1. Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.

    2. A01E1BVE01

      Check the valve seating position.


      1. Apply a light coat of Prussian blue (or white lead) to the valve face.

      2. Lightly press the valve against the seat. Do not rotate valve.

    3. Check the valve face and seat for the following:


      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 width below.

        Standard width
        1.2 to 1.6 mm (0.047 to 0.063 in.)

  11. INSPECT EXHAUST VALVE SEAT

    A01E0ZTE02

    1. Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.

    2. A01DWG5E01

      Check the valve seating position.


      1. Apply a light coat of Prussian blue (or white lead) to the valve face.

      2. Lightly press the valve against the seat. Do not rotate valve.

    3. Check the valve face and seat for the following:


      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 width below.

        Standard width
        1.6 to 2.0 mm (0.063 to 0.079 in.)

  12. INSPECT VALVE LIFTER

    A01DX93E01

    1. Using a micrometer, measure the lifter diameter.

      Standard lifter diameter
      30.966 to 30.976 mm (1.2191 to 1.2195 in.)
    2. A01DWLNE01

      Using a caliper gauge, measure the lifter bore diameter of the cylinder head.

      Standard lifter bore diameter
      31.000 to 31.021 mm (1.2205 to 1.2213 in.)

      If the lifter diameter is not as specified, check the oil clearance.

    3. Subtract the lifter diameter measurement from the lifter bore diameter measurement.

      Standard oil clearance
      0.024 to 0.055 mm (0.0009 to 0.0022 in.)
      Maximum oil clearance
      0.075 mm (0.0030 in.)

      If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head.

  13. INSPECT CYLINDER HEAD SET BOLT

    A01DW6BE01

    1. Using a vernier caliper, measure the minimum outside diameter of the compressed thread at the measuring point A.

      Standard outside diameter
      11.8 to 12.0 mm (0.465 to 0.472 in.)
      Minimum outside diameter
      11.6 mm (0.457 in.)

      If the outside diameter is less than the minimum, replace the bolt.

  14. INSPECT CAMSHAFT

    A01DXA2E01

    1. 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
        0.03 mm (0.0012 in.)

        If the circle runout is greater than the maximum, replace the camshaft.

    2. Inspect the cam lobe height.


      1. A01E1FGE01

        Using a micrometer, measure the cam lobe height.

        Standard cam lobe height
        47.180 to 47.280 mm (1.8575 to 1.8614 in.)
        Minimum cam lobe height
        46.76 mm (1.8409 in.)

        If the cam lobe height is less than the minimum, replace the camshaft.

    3. A01E2FUE01

      Inspect the journal diameter of the camshaft.


      1. Using a micrometer, measure the journal diameter of the camshaft for the camshaft bearing.

        Standard journal diameter
        27.969 to 27.985 mm (1.1011 to 1.1018 in.)

        If the journal diameter is not as specified, check the oil clearance.

    4. A01E2YPE01

      Check the oil clearance.


      1. Clean the bearing caps and journals.

      2. Check the bearings for flaking and scoring.

        If the bearings are damaged, replace the bearing caps and cylinder head as a set.

      3. Install the bearings to the bearing caps and cylinder head.

      4. Place the camshaft on the cylinder head.

      5. Lay a strip of Plastigage across each of the journals.

      6. A01DVVIE01

        Install the bearing caps.

        Note

        Do not turn the camshaft

      7. Remove the bearing caps.

      8. A01E293E01

        Measure the Plastigage at its widest point.

        Standard oil clearance
        0.025 to 0.062 mm (0.0010 to 0.0024 in.)
        Maximum oil clearance
        0.10 mm (0.0039 in.)

        If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing cap and cylinder head as a set.

      9. Completely remove the Plastigage.

      10. Remove the camshaft.

    5. A01E2XVE01

      Check the thrust clearance.


      1. Install the camshaft.

      2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

        Standard thrust clearance
        0.035 to 0.185 mm (0.014 to 0.073 in.)
        Maximum thrust clearance
        0.25 mm (0.0098 in.)

        If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing cap and cylinder head as a set.

    6. A01E22ME01

      Using a dial indicator, measure the backlash.


      1. Install the 2 camshafts.

      2. Using a dial indicator, measure the backlash.

        Standard backlash
        0.035 to 0.089 mm (0.0014 to 0.0035 in.)
        Maximum thrust clearance
        0.189 mm (0.0074 in.)

        If the backlash is greater than the maximum, replace the 2 camshafts.

      3. Remove the 2 camshafts.

  15. INSPECT NO. 2 CAMSHAFT

    A01E0Q1E01

    1. 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
        0.03 mm (0.0012 in.)

        If the circle runout is greater than the maximum, replace the camshaft.

    2. Inspect the cam lobe height.


      1. A01E1FGE01

        Using a micrometer, measure the cam lobe height.

        Standard cam lobe height
        48.070 t48.170 mm (1.8925 to 1.8965 in.)
        Minimum cam lobe height
        47.92 mm (1.8866 in.)

        If the cam lobe height is less than the minimum, replace the camshaft.

    3. A01E2FUE01

      Inspect the journal diameter of the camshaft.


      1. Using a micrometer, measure the journal diameter of the camshaft for the camshaft bearing.

        Standard journal diameter
        27.969 to 27.985 mm (1.1011 to 1.1018 in.)

        If the journal diameter is not as specified, check the oil clearance.

    4. A01DZP2E02

      Check the oil clearance.


      1. Clean the bearing caps and journals.

      2. Check the bearings for flaking and scoring.

        If the bearings are damaged, replace the bearing caps and cylinder head.

      3. Install the bearings to the bearing caps and cylinder head.

      4. Place the camshaft on the cylinder head.

      5. Lay a strip of Plastigage across each of the journals.

      6. A01E0PHE01

        Install the bearing caps.

        Note

        Do not turn the camshaft.

      7. Remove the bearing caps.

      8. A01DVTRE02

        Measure the Plastigage at its widest point.

        Standard oil clearance
        0.025 to 0.062 mm (0.0010 to 0.0024 in.)
        Maximum oil clearance
        0.10 mm (0.0039 in.)

        If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing cap and cylinder head as a set.

      9. Completely remove the Plastigage.

      10. Remove the camshaft.

    5. A01DWE3E01

      Check the thrust clearance.


      1. Install the camshaft.

      2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

        Standard thrust clearance
        0.035 to 0.185 mm (0.0014 to 0.0073 in.)
        Maximum thrust clearance
        0.25 mm (0.0098 in.)

        If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing cap and cylinder head as a set.