CYLINDER HEAD INSPECTION

PROCEDURE


  1. INSPECT CYLINDER HEAD SUB-ASSEMBLY


    1. Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head sub-assembly contacts the cylinder block sub-assembly, intake manifold and exhaust manifold converter sub-assembly (TWC: Front Catalyst).

      B007Y3KC02
      *a Bottom Side *b Intake Manifold Side
      *c Exhaust Manifold Converter Sub-assembly (Twc: Front Catalyst) Side - -
      Maximum Warpage
      Item Specified Condition
      Bottom side 0.05 mm (0.00197 in.)
      Intake Manifold side 0.10 mm (0.00394 in.)
      Exhaust manifold converter sub-assembly (TWC: Front Catalyst) side 0.10 mm (0.00394 in.)

      If the warpage is more than the maximum, replace the cylinder head sub-assembly.

    2. Using a dye penetrant, check the intake ports, exhaust ports and cylinder head sub-assembly surface for cracks.

      If cracks are found, replace the cylinder head sub-assembly.

  2. INSPECT COMPRESSION SPRING


    1. B007XFPC02
      *a Identification color

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

      Standard Free Length
      Paint Mark Specified Condition
      Type A White (Intake Side Compression Spring) 52.17 mm (2.05 in.)
      Type B Green (Intake Side Compression Spring) 52.67 mm (2.07 in.)
      Purple (Exhaust Side Compression Spring) 61.22 mm (2.41 in.)

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

      Tech Tips

      Type A and Type B can be distinguished by the paint mark of the intake side compression spring.

    2. B007X56C12
      *a 35 mm (1.38 in.)
      *b Deviation

      Using a steel square, measure the deviation of the compression spring at a point 35 mm (1.38 in.) from the bottom of the compression spring.

      Maximum Deviation
      1.22 mm (0.0480 in.)
      Maximum Angle
      2°

      If the deviation is more than the maximum, replace the compression spring.

  3. INSPECT INTAKE VALVE


    1. B007Y24

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

      Standard Stem Diameter
      5.470 to 5.485 mm (0.215 to 0.216 in.)

      If the valve stem diameter is not as specified, check the intake valve guide bush oil clearance.

    2. B007XQ9C16
      *a Margin Thickness

      Using a vernier caliper, measure the intake valve head margin thickness.

      Standard Margin Thickness
      1.0 mm (0.0394 in.)
      Minimum Margin Thickness
      0.50 mm (0.0197 in.)

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

    3. B007Y2OC14
      *a Overall Length

      Using a vernier caliper, measure the overall length of the intake valve.

      Standard Overall Length
      103.92 mm (4.09 in.)
      Minimum Overall Length
      103.42 mm (4.07 in.)

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

  4. INSPECT EXHAUST VALVE


    1. B007X8T

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

      Standard Stem Diameter
      5.465 to 5.480 mm (0.215 to 0.216 in.)

      If the valve stem diameter is not as specified, check the exhaust valve guide bush oil clearance.

    2. B007ZQQC02
      *a Margin Thickness

      Using a vernier caliper, measure the exhaust valve head margin thickness.

      Standard Margin Thickness
      1.0 mm (0.0394 in.)
      Minimum Margin Thickness
      0.50 mm (0.0197 in.)

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

    3. B007ZOTC14
      *a Overall Length

      Using a vernier caliper, measure the overall length of the exhaust valve.

      Standard Overall Length
      112.91 mm (4.45 in.)
      Minimum Overall Length
      112.41 mm (4.43 in.)

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

  5. INSPECT VALVE GUIDE BUSH OIL CLEARANCE


    1. B007YQ2

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

      Standard Valve Guide Bush Inside Diameter
      5.510 to 5.530 mm (0.217 to 0.218 in.)

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

      Standard Oil Clearance
      Item Specified Condition
      Intake Side 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
      Exhaust Side 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
      Maximum Oil Clearance
      Item Specified Condition
      Intake Side 0.08 mm (0.00315 in.)
      Exhaust Side 0.10 mm (0.00394 in.)

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

  6. INSPECT INTAKE VALVE SEAT


    1. Apply a light coat of Prussian blue to the valve face.

    2. B007YM9C18
      *a Width

      Lightly press the valve face against the intake valve seat.

      Tech Tips

      Do not rotate the intake valve.

    3. Check the valve face and intake valve seat by using the following procedure.


      1. If Prussian blue appears 360° around the entire valve face, the valve face is concentric. If not, resurface the intake valve.

      2. If Prussian blue appears 360° around the entire intake valve seat, the intake valve seat and valve face are concentric. If not, resurface the intake valve seat.

      3. Check that the intake valve seat contacts the middle of the valve face with the width between 1.0 and 1.4 mm (0.0394 and 0.0551 in.).

  7. INSPECT EXHAUST VALVE SEAT


    1. Apply a light coat of Prussian blue to the valve face.

    2. B007YNZC13
      *a Width

      Lightly press the exhaust valve face against the exhaust valve seat.

      Tech Tips

      Do not rotate the exhaust valve.

    3. Check the exhaust valve face and exhaust valve seat.


      1. Check that the contact surfaces of the exhaust valve seat and valve face are in the middle area of their respective surfaces, with the width between 1.2 and 1.6 mm (0.0472 and 0.0630 in.).

        If not, correct the exhaust valve seat.

      2. Check that the contact surfaces of the exhaust valve seat and valve face are even around the entire exhaust valve seat.

        If not, correct the exhaust valve seat.

  8. INSPECT CAMSHAFT THRUST CLEARANCE


    1. Inspect the camshaft and No. 2 camshaft.


      1. Install the No. 2 camshaft.

        Click here

      2. Install the camshaft.

        Click here

      3. Install camshaft bearing cap.

        Click here

      4. Install the camshaft housing sub-assembly to cylinder head sub-assembly.

      5. B007YJ5

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

        Standard Thrust Clearance
        Item Specified Condition
        Camshaft 0.060 to 0.200 mm (0.00236 to 0.00787 in.)
        No. 2 Camshaft 0.060 to 0.155 mm (0.00236 to 0.00610 in.)
        Maximum Thrust Clearance
        Item Specified Condition
        Camshaft 0.215 mm (0.00846 in.)
        No. 2 Camshaft 0.170 mm (0.00669 in.)

        If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly. If the thrust surface is damaged, replace the camshaft.