Cylinder Head Assembly: Service and Repair
Cylinder HeadREMOVAL
CYLINDER HEAD RH
1) Remove the engine from the vehicle.
2) Remove the intake manifold.
3) Remove the tumble generator valve assembly RH.
4) Remove the chain cover.
5) Remove the rocker cover RH.
6) Remove the cam carrier RH.
7) Remove the EGR pipe assembly from the water pipe assembly and the cylinder block RH.
8) Loosen the bolts holding the cylinder head RH equally, a little at a time in numerical sequence as shown in the figure, and while leaving the cylinder head bolts (1) and (4) engaged by three or four threads, remove the other cylinder head bolts.
NOTE:
Leaving the cylinder head bolts (1) and (4) engaged by three or four threads prevents the cylinder head RH from falling.
9) While tapping the cylinder head RH with a plastic hammer, separate it from cylinder block RH.
10) Remove the bolts (1) and (4) to remove cylinder head RH.
11) Remove the cylinder head gasket RH.
CAUTION:
Be careful not to scratch the mating surface of cylinder head and cylinder block.
12) Remove the liquid gasket from cylinder head RH and cam carrier RH.
CYLINDER HEAD LH
1) Remove the engine from the vehicle.
2) Remove the intake manifold.
3) Remove the tumble generator valve assembly LH.
4) Remove the chain cover.
5) Remove the rocker cover LH.
6) Remove the cam carrier LH.
7) Remove the bolt securing the A/C compressor bracket to the cylinder head LH, and remove the A/C compressor bracket.
8) Loosen the bolts holding the cylinder head LH equally, a little at a time in numerical sequence as shown in the figure, and while leaving the cylinder head bolts (1) and (4) engaged by three or four threads, remove the other cylinder head bolts.
NOTE:
Leaving the cylinder head bolts (1) and (4) engaged by three or four threads prevents the cylinder head LH from falling.
9) While tapping the cylinder head LH with a plastic hammer, separate it from cylinder block LH.
10) Remove the cylinder head bolts (1) and (4) to remove cylinder head LH.
11) Remove the cylinder head gasket LH.
CAUTION:
Be careful not to scratch the mating surface of cylinder head and cylinder block.
12) Remove the liquid gasket from cylinder head LH and cam carrier LH.
INSTALLATION
CYLINDER HEAD RH
1) Clean the bolt holes in the cylinder block RH.
CAUTION:
To avoid erroneous tightening of the bolts, clean out the bolt holes sufficiently by blowing with compressed air to eliminate engine coolant etc.
2) Apply liquid gasket to both sides of the cylinder head gasket RH as shown in the figure.
NOTE:
^ Use a new cylinder head gasket RH.
^ Before applying liquid gasket, degrease the mating surface of cylinder blocks RH and cylinder head RH.
^ Install within 5 min. after applying liquid gasket.
Liquid gasket:
THREE BOND 1217G (Part No. 0877Y0100) or equivalent
Liquid gasket applying diameter:
3±1 mm (0.1181±0.0394 in)
3) Attach the cylinder head gasket RH.
NOTE:
Check that liquid gasket RH is squeezed out from the cylinder head gasket.
4) Install the cylinder head RH to the cylinder block RH.
CAUTION:
Be careful not to scratch the mating surface of cylinder head RH and cylinder block RH.
(1) Clean the cylinder head bolt threads and apply sufficient engine oil to the washer and cylinder head bolts threads.
(2) Mount the cylinder head RH onto the cylinder block RH, and tighten all bolts with a torque of 29 Nm (3.0 kgf-m, 21.4 ft-lb) in numerical order as shown in the figure.
(3) Tighten all cylinder head bolts further with a torque of 100 Nm (10.2 kgf-m, 73.8 ft-lb) in numerical order as shown in the figure.
CAUTION:
If the bolt makes stick-slip sound during tightening, repeat the procedure from step 1). In that case, the cylinder head gasket RH can be reused. But it is necessary to remove liquid gasket completely from cylinder block RH, cylinder head RH and cylinder head gasket RH and re-apply to them.
(4) Loosen all cylinder head bolts 180° in numerical order as shown in the figure, and then loosen all cylinder head bolts 180° further in numerical order as shown in the figure.
(5) Tighten all cylinder head bolts with a torque of 42 Nm (4.3 kgf-m, 31.0 ft-lb) in numerical order as shown in the figure.
(6) Using ST2, tighten all cylinder head bolts with specified angle in numerical order as shown in the figure.
NOTE:
Attach the magnet used for securing the ST2 (ANGLE GAUGE) to ST1.
ST1 499817100 ENGINE STAND
ST2 18854AA000 ANGLE GAUGE
Tightening angle:
80°±2°
(7) Using ST2, tighten the cylinder head bolts (2 places) with specified angle in numerical order as shown in the figure.
NOTE:
Attach the magnet used for securing the ST2 (ANGLE GAUGE) to ST1.
ST1 499817100 ENGINE STAND
ST2 18854AA000 ANGLE GAUGE
Tightening angle:
75°±2°
(8) Using ST2, tighten the cylinder head bolts (4 places) with specified angle in numerical order as shown in the figure.
NOTE:
^ After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely remove any squeezed-out liquid gasket.
^ Attach the magnet used for securing the ST2 (ANGLE GAUGE) to ST1.
ST1 499817100 ENGINE STAND
ST2 18854AA000 ANGLE GAUGE
Tightening angle:
30°±2°
5) Install the EGR pipe assembly to the water pipe assembly and the cylinder block RH.
NOTE:
Use a new gasket.
Tightening torque:
T1: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
T2: 51 Nm (5.2 kgf-m, 37.6 ft-lb)
6) Install the cam carrier RH.
7) Install the rocker cover RH.
8) Install the chain cover.
9) Install the tumble generator valve assembly RH.
10) Install the intake manifold.
11) Install the engine to the vehicle.
CYLINDER HEAD LH
1) Clean the bolt holes in the cylinder block LH.
CAUTION:
To avoid erroneous tightening of the bolts, clean out the bolt holes sufficiently by blowing with compressed air to eliminate engine coolant etc.
2) Apply liquid gasket to both sides of the cylinder head gasket LH as shown in the figure.
NOTE:
^ Use a new cylinder head gasket LH.
^ Before applying liquid gasket, degrease the mating surface of cylinder blocks LH and cylinder head LH.
^ Install within 5 min. after applying liquid gasket.
Liquid gasket:
THREE BOND 1217G (Part No. 0877Y0100) or equivalent
Liquid gasket applying diameter:
3±1 mm (0.1181±0.0394 in)
3) Attach the cylinder head gasket LH.
NOTE:
Check that liquid gasket is squeezed out from the cylinder head gasket LH.
4) Install the cylinder head LH to the cylinder block LH.
CAUTION:
Be careful not to scratch the mating surface of cylinder head LH and cylinder block LH.
(1) Clean the cylinder head bolt threads and apply sufficient engine oil to the washer and cylinder head bolts threads.
(2) Mount the cylinder head LH onto the cylinder block LH, then tighten all bolts with a torque of 29 Nm (3.0 kgf-m, 21.4 ft-lb) in numerical order as shown in the figure.
(3) Tighten all cylinder head bolts further with a torque of 100 Nm (10.2 kgf-m, 73.8 ft-lb) in numerical order as shown in the figure.
CAUTION:
If the bolt makes stick-slip sound during tightening, repeat the procedure from step 1). In that case, the cylinder head gasket LH can be reused. But it is necessary to remove liquid gasket completely from cylinder block LH, cylinder head LH and cylinder head gasket LH and re-apply to them.
(4) Loosen all cylinder head bolts 180° in numerical order as shown in the figure, and then loosen all cylinder head bolts 180° further in numerical order as shown in the figure.
(5) Tighten all cylinder head bolts with a torque of 42 Nm (4.3 kgf-m, 31.0 ft-lb) in numerical order as shown in the figure.
(6) Using ST2, tighten all cylinder head bolts with specified angle in numerical order as shown in the figure.
NOTE:
Attach the magnet used for securing the ST2 (ANGLE GAUGE) to ST1.
ST1 499817100 ENGINE STAND
ST2 18854AA000 ANGLE GAUGE
Tightening angle:
80°±2°
(7) Using ST2, tighten the cylinder head bolts (2 places) with specified angle in numerical order as shown in the figure.
NOTE:
Attach the magnet used for securing the ST2 (ANGLE GAUGE) to ST1.
ST1 499817100 ENGINE STAND
ST2 18854AA000 ANGLE GAUGE
Tightening angle:
75°±2°
(8) Using ST2, tighten the cylinder head bolts (4 places) with specified angle in numerical order as shown in the figure.
NOTE:
^ After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely remove any squeezed-out liquid gasket.
^ Attach the magnet used for securing the ST2 (ANGLE GAUGE) to ST1.
ST1 499817100 ENGINE STAND
ST2 18854AA000 ANGLE GAUGE
Tightening angle:
30°±2°
5) Set the A/C compressor bracket to the cylinder head LH, and tighten the bolts in numerical order as shown in the figure.
Tightening torque:
36 Nm (3.7 kgf-m, 26.6 ft-lb)
6) Install the cam carrier LH.
7) Install the rocker cover LH.
8) Install the chain cover.
9) Install the tumble generator valve assembly LH.
10) Install the intake manifold.
11) Install the engine to the vehicle.
DISASSEMBLY
1) Remove the chain cover securing bolt from the cylinder head LH.
2) Remove the stud bolts from the cylinder head.
3) Remove the valve collet, valve, valve spring retainer, valve spring and valve spring seat from the cylinder head RH.
CAUTION:
During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head RH.
NOTE:
^ Mark each part to prevent confusion.
^ Keep all the removed parts in order for re-installing in their original positions.
(1) Compress the valve spring and remove the valve collet using ST.
ST 0920287002000 REMOVER AND REPLACER
(2) Remove valve, valve spring retainer, valve spring and valve spring seat.
4) Remove the valve collet, valve, valve spring retainer, valve spring and valve spring seat from the cylinder head LH.
5) Remove the valve oil seal from the valve guide.
CAUTION:
^ During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head RH.
^ Use special care not to damage the cylinder head RH and guide during work.
6) For cylinder head LH, remove the valve oil seal in the same manner.
ASSEMBLY
1) Using the ST, install the valve oil seal to the valve guide.
CAUTION:
^ During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head RH.
^ Use special care not to damage the cylinder head RH and guide during work.
^ When installing the valve oil seal, press the ST with hands to install it and never drive the ST with a plastic hammer, otherwise the valve oil seal can be damaged.
NOTE:
^ Use a new valve oil seal.
^ Apply engine oil to valve oil seal before installing.
^ The intake valve oil seals and exhaust valve oil seals are distinguished by their colors.
Identification colors:
Intake [Gray]
Exhaust [Green]
ST 18261AA010 VALVE OIL SEAL GUIDE
2) For cylinder head LH, install the valve oil seal in the same manner.
3) Install the valve spring seat, valve spring, valve spring retainer, valve and valve collet to the cylinder head RH.
CAUTION:
During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head RH.
(1) Set the valve spring seat, valve spring and valve spring retainer onto the cylinder head RH.
NOTE:
Be sure to install the valve spring with its close-coiled end facing the cylinder head side.
(2) Coat the valve stem of each valve with engine oil and insert the valve into valve guide.
NOTE:
When inserting the valve into valve guide, use special care not to damage the oil seal lip.
(3) Compress the valve spring and install the valve collet using ST.
ST 0920287002000 REMOVER AND REPLACER
4) Install the valve spring seat, valve spring, valve spring retainer, valve and valve collet to the cylinder head LH.
5) Lightly tap the valve spring retainer with a plastic hammer, and make sure that the valve collet is securely attached.
6) Install the stud bolts onto cylinder heads.
Tightening torque:
T1: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
T2: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
7) Install the chain cover securing bolt to the cylinder head LH.
Tightening torque:
6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
INSPECTION
CYLINDER HEAD
1) Visually inspect to make sure that there are no cracks, scratches or other damage.
2) Use liquid penetrant tester on the important sections to check for fissures.
3) Check that there are no marks of gas leaking or water leaking on gasket attachment surface.
4) Check the warping of the cylinder head mating surface that mates with cylinder block using a straight edge (A) and thickness gauge (B) at the locations shown in the figure. If it exceeds the limit, correct the surface by grinding it with a surface grinder or replace the cylinder head.
NOTE:
Measurement should be performed at a temperature of 20°C (68°F).
Warping limit:
0.035 mm (0.0014 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder head:
98.5 mm (3.878 in)
NOTE:
If the cylinder head bolt tightening torques and angle tightening is uneven, warpage of the cylinder head may occur. During installation work, make sure that tightening torque and angle tightening work is performed precisely so that it is tightened evenly.
VALVE SEAT
Inspect the intake and exhaust valve seats of cylinder head, and correct the contact surfaces with a valve seat cutter if they are defective or when valve guides are replaced.
Contacting width W between valve and valve seat:
Intake
Standard
0.8 - 1.6 mm (0.031 - 0.063 in)
Exhaust
Standard
1.1 - 1.7 mm (0.043 - 0.067 in)
VALVE GUIDE
1) Check the clearance between valve guide and valve stem. Check the clearance between valve guide and valve stem by measuring the outer diameter of valve stem and the inner diameter of valve guide respectively.
(1) Measure the outer diameter of valve stem with a micrometer. If it is not within the standard, replace the valve.
NOTE:
^ Measurement should be performed at a temperature of 20°C (68°F).
^ Measure the outer diameter of the valve stem at the three locations as shown in the figure, and read the value of most worn location.
^ If the valve is replaced, put a small amount of grinding compound on the valve seat surface of cylinder head, and lap the valve and valve seat surfaces.
Valve stem outer diameters:
Intake
Standard
5.455 - 5.470 mm (0.2148 - 0.2154 in)
Exhaust
Standard
5.445 - 5.460 mm (0.2144 - 0.2150 in)
(2) Using a caliper gauge, measure the inner diameter of valve guide. If it is not within the standard, replace the valve guide. For replacement procedure, refer to step 2).
NOTE:
Measurement should be performed at a temperature of 20°C (68°F).
Valve guide inner diameter:
Standard
5.500 - 5.512 mm (0.2165 - 0.2170 in)
(3) Calculate the clearance between valve guide and valve stem.
Clearance between the valve guide and valve stem:
Intake
Standard
0.030 - 0.057 mm (0.0012 - 0.0022 in)
Exhaust
Standard
0.040 - 0.067 mm (0.0016 - 0.0026 in)
2) If the clearance between valve guide and valve stem exceeds the standard, replace the valve guide or valve, whichever shows the greater amount of wear or damage. For replacement procedure of valve guide, refer to the following.
NOTE:
If the valve is replaced, put a small amount of grinding compound on the valve seat surface of cylinder head, and lap the valve and valve seat surfaces.
(1) Insert ST into the valve guide with the combustion chamber upward and remove the valve guide using plastic hammer.
CAUTION:
^ Place a wood board wrapped with a waste cloth to stabilize the cylinder head before work.
^ Use special care not to damage the cylinder head during work.
ST 499765700 VALVE GUIDE REMOVER AND INSTALLER
(2) Before installing the valve guide, make sure that neither scratches nor damages exist on the inner surface of valve guide holes in cylinder head.
(3) Draw a reference line (A) for insert on the valve guide using a marker as shown in the figure.
NOTE:
^ Use a new valve guide.
^ A reference line for insert is used as a guide when tapping-in the valve guide.
Valve guide inserting reference line position L:
15 mm (0.5906 in)
(4) Apply a enough coat of engine oil to the valve guide, and set the valve guide on the cylinder head with the combustion chamber downward.
(5) Insert the ST into the valve guide, and tap-in the valve guide to the reference line (A) for insert using plastic hammer.
CAUTION:
^ During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head.
^ Use special care not to damage the cylinder head during work.
ST 499765700 VALVE GUIDE REMOVER AND INSTALLER
(6) Measure the valve guide protrusion amount "L" as shown in the figure using a caliper gauge. Insert the ST into the valve guide again, and tap-in the valve guide so that it is positioned within standard by referring to the measured value using plastic hammer.
CAUTION:
^ During work, place a waste cloth, etc. to avoid scratching the mating surface of the cylinder head.
^ Use special care not to damage the cylinder head during work.
NOTE:
Be careful not to tap-in excessively by repeating the steps of Tapping-in -> Measurement -> Tapping-in -> Measurement ... when installing the valve guide.
ST 499765700 VALVE GUIDE REMOVER AND INSTALLER
Valve guide protrusion amount L:
Standard
11.4 - 11.8 mm (0.449 - 0.465 in)
(7) Ream the inside of valve guide with the combustion chamber upward using ST. Put the ST in valve guide, and rotate the ST slowly clockwise while pushing it lightly. Bring the ST back while rotating it clockwise.
CAUTION:
^ Place a wood board wrapped with a waste cloth to stabilize the cylinder head before work.
^ Use special care not to damage the cylinder head during work.
NOTE:
^ Apply engine oil to the ST when reaming.
^ If the inner surface of valve guide is damaged, the edge of ST should be slightly ground with oil stone.
^ If the inner surface of valve guide becomes lustrous and the ST does not chip, use a new ST or remedy the ST.
ST 499765900 VALVE GUIDE REAMER
(8) After reaming, clean the valve guide to remove chips.
(9) Recheck the contact condition between valve and valve seat after replacing the valve guide.
INTAKE VALVE AND EXHAUST VALVE
1) Check the valve flange and valve stem for damage, wear or deformation.
2) Check the height "H" in the figure using a caliper gauge. If it is not within the standard, replace the valve.
NOTE:
^ It is possible to differentiate between the intake valve and the exhaust valve by their overall length.
Valve overall length:
Intake
103.3 mm (4.067 in)
Exhaust
94.1 mm (3.705 in)
^ If the valve is replaced, put a small amount of grinding compound on the valve seat surface of cylinder head, and lap the valve and valve seat surfaces.
Head edge thickness H:
Intake (A)
Standard
0.8 - 1.2 mm (0.031 - 0.047 in)
Exhaust (B)
Standard
1.0 - 1.4 mm (0.039 - 0.055 in)
VALVE SPRING
1) Check the valve spring for damage and deformation.
2) Check the valve spring free length, tension and squareness. If it is not within the standard, replace the valve spring.
NOTE:
To check the squareness of the valve spring, stand the valve spring on a surface plate and check its deflection at the top of the valve spring using a try square.
Free length:
Standard
41.06 mm (1.617 in)
Tension/spring height:
Set
Standard
182 - 210 N (18.56 - 21.41 kgf, 40.92 - 47.22 lbf)/33.0 mm (1.299 in)
Lift
Standard
552 - 610 N (56.29 - 62.20 kgf, 124.11 - 137.15 lbf)/22.0 mm (0.866 in)
Squareness:
Standard
2.5°, 1.8 mm (0.071 in) or less
VALVE SHIM
1) Visually check the valve shim for damage.
2) Check the clearance between valve shim and valve stem end. Check the clearance between valve shim and valve stem end by measuring the inner diameter of valve shim and the outer diameter of valve stem end respectively.
(1) Using a caliper gauge, measure the inner diameter of valve shim. If it is not within the standard, replace the valve shim.
NOTE:
^ Measurement should be performed at a temperature of 20°C (68°F).
^ If the valve shim has to be replaced, check the cam clearance and replace with the suitable valve shim. Testing and Inspection
Valve shim inner diameter:
Standard
5.500 - 5.560 mm (0.2165 - 0.2189 in)
(2) Measure the outer diameter of valve stem end with a micrometer. If it is not within the standard, replace the valve.
NOTE:
^ Measurement should be performed at a temperature of 20°C (68°F).
^ If the valve is replaced, put a small amount of grinding compound on the valve seat surface of cylinder head, and lap the valve and valve seat surfaces.
Valve stem end outer diameter:
Intake
Standard
5.455 - 5.470 mm (0.2148 - 0.2154 in)
Exhaust
Standard
5.445 - 5.460 mm (0.2144 - 0.2150 in)
(3) Calculate the clearance between valve shim and valve stem end. If the clearance exceeds the standard, replace the valve shim or valve, whichever shows the greater amount of wear or damage.
NOTE:
^ If the valve is replaced, put a small amount of grinding compound on the valve seat surface of cylinder head, and lap the valve and valve seat surfaces.
^ If the valve shim has to be replaced, check the cam clearance and replace with the suitable valve shim. Testing and Inspection
Clearance between the valve and valve stem end:
Intake
Standard
0.030 - 0.105 mm (0.0012 - 0.0041 in)
Exhaust
Standard
0.040 - 0.115 mm (0.0016 - 0.0045 in)