Cylinder head cover

Repair Procedures

Removal

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

    1. Using a triple square wrench, gradually loosen and remove the 8 cylinder head bolts in several passes in the sequence shown. Remove the 8 cylinder head bolts and plate washers.

       

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

       

Disassembly

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

   

2. 2
   Remove the valves.

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

      

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

      

Inspection

1. 1
   Inspect for flatness. Using a precision straightedge and feeler gauge, measure the contact surface with the cylinder block and inspect the manifolds for distortion. If the flatness exceeds the maximum, replace the cylinder head. Cylinder head gasket surface flatness Standard: less than 0.05 mm (0.0020 in.) 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 ports, exhaust ports and cylinder block surface for cracks. If any cracks are found, 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 O.D. 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 measurement from the valve guide inside diameter measurement. Valve 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 to the correct valve face angle.

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

   2. Check the valve face for wear. 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, replace the valve.

      Margin 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 tip for wear. If the valve stem tip is worn, replace the valve.
5. 5
   Inspect the valve seats.

   1. Check the valve seat for signs of overheating and improper contact with the valve face. If the valve seat is worn, replace the cylinder head.
   2. Before resurfacing the seat, check the valve guide for wear. If the valve guide is worn, replace the cylinder head.
   3. Resurface the valve seat using a grinder or cutter. The valve seat contact width must be within specification and 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.) Out-of-square: 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 outer 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 bore in the cylinder head. Lifter bore inside diameter Intake/Exhaust: 28.000-28.025 mm (1.1024-1.1033 in.)
9. 9
   Subtract the MLA outer diameter from the lifter bore inside diameter. MLA-to-lifter bore clearance [Limit] Intake/Exhaust: 0.020-0.061 mm (0.0008-0.0024 in.)

Installation

1. 1
   Install the valves.

   1. Using SST (09222-1S100), install a new valve stem seal.

      

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

      

   4. Lightly tap the end of each valve stem two or three times with a wooden mallet handle to ensure proper seating of the valve and keeper.
2. 2
   Install the mechanical lash adjuster (A).

   

Installation

1. 1
   Install the cylinder head gasket.

   1. The sealant application areas on the cylinder head gasket, cylinder block and timing chain lower cover must be cleaned of engine oil and similar contaminants.
   2. Before installing the cylinder head gasket, apply sealant to the upper 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 onto the cylinder block, apply sealant to the upper surface of the cylinder head gasket and assemble within five minutes. Bead width: 2.0-3.0 mm (0.08-0.12 in.) Sealant: TB1217H or LOCTITE 5900H.

      

   5. Remove any sealant that squeezes out after assembling the cylinder head.
2. 2
   Install the cylinder head assembly.

   1. Carefully install the cylinder head (A) so as not to damage the gasket.

      

   2. Tighten the cylinder head bolts and washers in several passes in the sequence shown. Tightening torque: 12.7-16.7 N·m + 90-95° + 120-125°

      

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