CYLINDER HEAD Repair Procedures

DEPOSIT

1. 1
   Remove the engine cover. (Refer to Engine and Transaxle - "Engine Cover")
2. 2
   Remove the engine undercover. (Refer to Engine and Transaxle Assembly - "Engine Undercover")
3. 3
   Drain the engine coolant. (Refer to Cooling System - "Cooling")
4. 4
   Remove the intake manifold. (Refer to Exhaust and Intake System - "Intake Manifold")
5. 5
   Remove the exhaust manifold. (Refer to Intake and Exhaust System - "Turbocharger and Exhaust Manifold")
6. 6
   Remove the water temperature control unit. (Refer to Cooling System - "Water Temperature Control")
7. 7
   Remove the vacuum pump. (Refer to Cylinder Head Assembly - "Vacuum Pump")
8. 8
   Remove the cylinder head cover. (Refer to Cylinder Head - "Cylinder Head Cover")
9. 9
   Remove the fuel feed pipe. (Refer to Engine Control/Fuel System - "Fuel Hose")
10. 10
    Remove the timing chain. (Refer to Valve Timing System - Timing Chain)
11. 11
    Remove the camshaft. (Refer to Cylinder Head - "CVVT and Camshaft")
12. 12
    Remove the intake and exhaust oil control valves (OCV). (Refer to Engine Control System/Fuel System - "Engine Oil Control Valve CVVT (OCV)").
13. 13
    Remove the camshaft position sensor (CMPS). (Refer to Fuel System/Engine Control - "Camshaft Position Sensor (CMPS)").
14. 14
    Remove the cylinder head.

    1. Using a square socket, loosen the 8 cylinder head bolts evenly and in several passes, in the sequence shown. Remove the 8 cylinder head bolts and plate washers.

       

    2. Lift the cylinder head (A) off the guide pins on the cylinder block and place it on wooden blocks and a workbench.
    3. Remove the cylinder head gasket (B).

       

DISASSEMBLY

1. 1
   Remove the MLA (mechanical lash adjuster) (A).

   

2. 2
   Remove the valves.

   1. Using SST (09222-3K000, 09222-3K100), compress the valve spring and remove the valve cotter.

      

   2. Remove the spring retainer.
   3. Remove the valve spring.
   4. Remove the valve.
   5. Using special service tool (09222-29000), remove the valve stem seal.

      

Inspection

1. 1
   Inspect the cylinder head flatness. Using a straightedge and feeler gauge, measure the mating surfaces of the cylinder block and manifolds to check for distortion. Cylinder head gasket surface flatness Standard: less than 0.05 mm (0.0020 in.) Limit: less than 0.02 mm (0.0008 in.)/100 x 100 Manifold gasket surface flatness Standard: less than 0.1 mm (0.0039 in.)

   

   

   

   

2. 2
   Inspect for cracks. Check the combustion chambers, intake and exhaust ports and the cylinder block surface for cracks. If cracked, replace the cylinder head.
3. 3
   Inspect the valve stems and valve guides.

   1. Using a caliper gauge, measure the inside diameter of the valve guide. Valve guide inside diameter Intake/Exhaust: 5.500 - 5.512 mm (0.2165 - 0.2170 in.)

      

   2. Using a micrometer, measure the diameter of the valve stem. Valve stem outside diameter Intake: 5.465 - 5.480 mm (0.2151 - 0.2157 in.) Exhaust: 5.448 - 5.460 mm (0.2144 - 0.2149 in.)

      

   3. Subtract the valve stem diameter from the valve guide inside diameter. Stem-to-guide clearance Intake: 0.020 - 0.047 mm (0.00078 - 0.00185 in.) Exhaust: 0.040 - 0.064 mm (0.00157 - 0.00251 in.)
4. 4
   Inspect the valves.

   1. Make sure the valve face is ground at the correct angle to the contact surface.

      Valve face angle: Intake/Exhaust: 45.25° - 45.75°

   2. Make sure the valve face is not damaged. If the valve face is worn, replace the valve.
   3. Check the valve head margin thickness. If the margin thickness is less than the minimum value, replace the valve.

      Margin thickness Intake: 1.5 mm (0.0590 in.) Exhaust: 1.75 mm (0.0688 in.)

      

   4. Check the valve length.

      Overall length Intake: 92.85 mm (3.6555 in.) Exhaust: 93.37 mm (3.6759 in.)

   5. Check the valve stem end surface for damage. If the valve stem end is worn, replace the valve.
5. 5
   Inspect the valve seats.

   1. Check the valve seat for overheating or contact with the valve face. If the valve seat is worn, replace the cylinder head.
   2. Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace the cylinder head.
   3. Recondition the valve seat using a valve seat reamer or valve seat cutter. The valve seat contact width must meet the specifications and be centered on the valve face. Valve seat contact width: Intake: 0.85 - 1.15 mm (0.0334 - 0.0452 in.) Exhaust: 1.35 - 1.65 mm (0.0531 - 0.0649 in.) Valve seat angle: Intake/Exhaust: 44.75° - 45.10°
6. 6
   Inspect the valve springs.

   1. Using a steel square, measure the valve spring squareness.
   2. Using a caliper gauge, measure the free length of the valve spring. Valve spring free length: 47.9 mm (1.8858 in.) Squareness: 1.5° (MAX.)

      

7. 7
   Inspect the MLA. Using a micrometer, measure the outside diameter of the MLA. MLA outside diameter Intake/Exhaust: 27.964 - 27.980 mm (1.1010 - 1.1016 in.)

   MLA outside diameter Intake/Exhaust: 27.964 - 27.980 mm (1.1010 - 1.1016 in.)

8. 8
   Using a caliper gauge, measure the inside diameter of the MLA tappet bore in the cylinder head. Tappet bore inside diameter Intake/Exhaust: 28.000 - 28.025 mm (1.1024 - 1.1033 in.)
9. 9
   Subtract the MLA outside diameter from the tappet bore inside diameter. MLA-to-bore clearance [Limit] Intake/Exhaust: 0.020 - 0.061 mm (0.0008 - 0.0024 in.)

Installation

1. 1
   Install the valves.

   1. Using special service tool (09222-1S100), install a new valve stem seal.

      

   2. Install the valve, valve spring and spring retainer.
   3. Using SST (09222-3K000, 09222-3K100), compress the spring and install the valve cotters. After installing the valves, make sure the cotters are seated correctly before releasing the valve spring compression.

      

   4. Lightly tap the end of each valve stem two or three times with a wooden mallet to make sure the valve and retainer are installed correctly.
2. 2
   Install the MLA (mechanical lash adjuster) (A).

   

REMEDY

1. 1
   Install the cylinder head gasket.

   1. Make sure there is no engine oil on the cylinder head gasket contact surface, cylinder block, timing chain lower cover, etc.
   2. Before installing the cylinder head gasket, apply liquid gasket to the top surface of the cylinder block and install the gasket within five minutes.

      Bead width: 2.0 ~ 3.0 mm (0.08 ~ 0.12 in.)

      

   3. Install the cylinder head gasket (A) on the cylinder block.

      

   4. After installing the cylinder head gasket on the cylinder block, apply liquid gasket to the top surface of the gasket and assemble the cylinder head within five minutes. Bead width: 2.0 ~ 3.0 mm (0.08 ~ 0.12 in.) Sealant: TB1217H or LOCTITE 5900H.

      

   5. Remove any excess sealant after assembling the cylinder head.
2. 2
   Install the cylinder head assembly.

   1. Carefully place the cylinder head (A) in position, taking care not to damage the gasket.

      

   2. Using SST 09221-4A000, tighten the cylinder head bolts and dome washers several times in the order shown. Torque: 12.7 ~ 16.7 N·m +90~95°+120~125°

      

3. 3
   Install the remaining parts in the reverse order of removal.