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 and manifolds.

      B006B5FC02
      *a Cylinder Head Sub-assembly Lower Side *b Intake Manifold Side
      *c Turbocharger Sub-assembly Side - -
      Maximum Warpage
      Item Specified Condition
      Cylinder Head Sub-assembly Lower Side 0.05 mm (0.00197 in.)
      Intake Manifold Side 0.10 mm (0.00394 in.)
      Turbocharger Sub-assembly Side 0.10 mm (0.00394 in.)

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

  2. INSPECT CYLINDER HEAD FOR CRACKS


    1. B006ALD

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

      Tech Tips

      If cracked, replace the cylinder head sub-assembly.

  3. INSPECT INTAKE VALVE


    1. B006GIG

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

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

      Tech Tips

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

    2. B006A5VC02
      *a Margin Thickness

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

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

      Tech Tips

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

    3. B006D7NC02
      *a Overall Length

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

      Standard Overall Length
      104.45 mm (4.11 in.)
      Minimum Overall Length
      103.95 mm (4.09 in.)

      Tech Tips

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

  4. INSPECT EXHAUST VALVE


    1. B006G6D

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

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

      Tech Tips

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

    2. B006FZVC02
      *a Margin Thickness

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

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

      Tech Tips

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

    3. B006DIKC02
      *a Overall Length

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

      Standard Overall Length
      108.7 mm (4.28 in.)
      Minimum Overall Length
      108.2 mm (4.26 in.)

      Tech Tips

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

  5. INSPECT INTAKE VALVE SEAT


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

    2. Lightly press the valve face against the intake valve seat.

      Note

      Do not rotate the intake valve while pressing it.

    3. B006C34C02
      *a Width

      Check the valve face and intake valve seat by using the following procedure:


      1. If Prussian blue appears 360° around the entire intake valve face, the valve face is concentric.

        Tech Tips

        If the valve face is not concentric, replace the intake valve.

      2. If Prussian blue appears 360° around the entire intake valve seat, the intake valve seat and valve face are concentric.

        Tech Tips

        If the valve face is not concentric, resurface the intake valve seat.

      3. Measure the width of the contact area of the intake valve seat and valve face.

        Standard Width
        1.1 to 1.5 mm (0.0433 to 0.0591 in.)

  6. INSPECT EXHAUST VALVE SEAT


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

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

      Note

      Do not rotate the exhaust valve while pressing it.

    3. B006EORC02
      *a Width

      Check the valve face and exhaust valve seat by using the following procedure:


      1. If Prussian blue appears 360° around the entire exhaust valve face, the valve face is concentric.

        Tech Tips

        If the valve face is not concentric, replace the exhaust valve.

      2. If Prussian blue appears 360° around the entire exhaust valve seat, the exhaust valve seat and valve face are concentric.

        Tech Tips

        If the valve face is not concentric, resurface the exhaust valve seat.

      3. Measure the width of the contact area of the exhaust valve seat and valve face.

        Standard Width
        1.3 to 1.7 mm (0.0512 to 0.0669 in.)

  7. INSPECT CYLINDER HEAD INTAKE VALVE COMPRESSION SPRING


    1. B006EQS

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

      Standard Free Length
      53.50 mm (2.11 in.)

      Note

      Compression springs come in 2 different lengths. Make sure all compression springs are the same length when replacing them.

    2. B006C7XC02
      *a Deviation
      *b 40 mm (1.57 in.)

      Using a steel square, measure the deviation of the cylinder head intake compression spring.

      Maximum Deviation (Reference)
      1.0 mm (0.0394 in.)

      Tech Tips

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

  8. INSPECT CYLINDER HEAD EXHAUST VALVE COMPRESSION SPRING


    1. B006EQS

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

      Standard Free Length
      57.78 mm (2.27 in.)

      Note

      Compression springs come in 2 different lengths. Make sure all compression springs are the same length when replacing them.

    2. B006C7XC02
      *a Deviation
      *b 40 mm (1.57 in.)

      Using a steel square, measure the deviation of the cylinder head exhaust compression spring.

      Maximum Deviation (Reference)
      1.0 mm (0.0394 in.)

      Tech Tips

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

  9. INSPECT VALVE GUIDE BUSH OIL CLEARANCE


    1. B006FT4

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

      Tech Tips

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