System Specifications
Cylinder Head Assembly 2.0L:
VALVES 2.0L:
Cylinder Head Assembly
Valve
Valve length
Intake 114.34 mm (4.5016 inch)
Exhaust 116.8 mm (4.5984 inch)
Stem 0.D.
Intake 5.965-5.98 mm (0.2348-0.2354 inch)
Exhaust 5.950-5.965 mm (0.2343-0.2348 inch)
Face angle thickness of valve head (Margin)
Intake
Specification 1.15 mm (0.0452 inch)
Limit 0.8 mm (0.031 inch)
Exhaust
Specification 1.35 mm (0.0531 inch)
Limit 1.0 mm (0.039 inch)
Valve stem to valve guide clearance
Intake
Specification 0.02-0.05 mm (0.0008-0.0019 inch)
Limit (0.10 mm 0.0039 inch)
Exhaust
Specification 0.035-0.065 mm (0.0014-0.0026 inch)
Limit 0.13 mm (0.0051 inch)
VALVE GUIDE OVERSIZES:
VALVE SEAT INSERT OVERSIZES:
Valve guide
Installed dimension O.D.
Intake 46 mm (1.811 inch)
Exhaust 54.5 mm (2.146 inch)
Service oversize 0.05, 0.25, 0.50 mm (0.002, 0.010, 0.020 inch) oversize
Valve seat
Width of seat contact
Intake 1.1-1.5 mm (0.043-0.059 inch)
Exhaust 1.3-1.7 mm (0.051-0.066 inch)
Seat angle 45°
Oversize 0.3, 0.6 mm (0.012, 0.024 inch) oversize
Valve spring
Free length 48.86 mm (1.9236 inch)
Load 18.3 kg / 39 mm, 40.0 kg / 30.5 mm
Installed height 39 mm (1.5354 inch)
Squareness 1.50 or less
Valve clearance (cold)
Intake
Specification 0.20 mm (0.0079 inch)
Limit 0.12-0.28 mm (0.0047-0.0110 inch)
Exhaust
Specification 0.28 mm (0.0110 inch)
Limit 0.20-0.36 mm (0.0079-0.0142 inch)
Cylinder head
Flatness of gasket surface
Specification Max. 0.03 mm (0.0012 inch)
Limit 0.06 mm (0.0024 inch)
Flatness of manifold mounting surface
Specification Max. 0.15 mm (0.0059 inch)
Limit Max. 0.03 mm (0.0118 inch)
Oversize rework dimensions of valve seat hole
Intake
0.3 mm (0.012 inch) O.S. 33.300-33.325 mm (1.3110-1.3120 inch)
0.6 mm (0.024 inch) O.S. 33.600-33.625 mm (1.3228-1.3238 inch)
Exhaust
0.3 mm (0.012 inch) O.S. 28.800-28.821 mm (1.1338-1.1346 inch)
0.6 mm (0.024 inch) O.S. 29.100-29.121 mm (1.1456-1.1465 inch)
Oversize rework dimensions of valve guide hole (both intake and exhaust)
0.05 mm (0.002 inch) O.S. 11.50-11.518 mm (0.453-0.4535 inch)
0.25 mm (0.010 inch) O.S. 11.05-11.068 mm (0.435-0.4357 inch)
0.50 mm (0.020 inch) O.S. 11.25-11.268 mm (0.443-0.4436 inch)
TIGHTENING TORQUE
Intake and Exhaust system
Intake manifold to cylinder head nuts and bolts 16-23 Nm (160-230 kg-cm, 12-17 ft. lbs.)
Intake manifold stay to cylinder block bolts 18-25 Nm (180-250 kg-cm, 13-18 ft. lbs.)
Throttle body to surge tank nuts 15-20 Nm (150-200 kg-cm, 11-14 ft. lbs.)
Exhaust manifold to cylinder head nuts 43-55 Nm (430-550 kg-cm, 32-40 ft. lbs.)
Exhaust manifold cover to exhaust manifold bolts 15-20 Nm (150-200 kg-cm, 11-14 ft. lbs.)
Oxygen sensor to exhaust manifold 50-60 Nm (500-600 kg-cm, 36-43 ft. lbs.)
Front exhaust pipe to exhaust manifold nuts 30-40 Nm (300-400 kg-cm, 22-29 ft. lbs.)
Cylinder Head Bolt Sequence:
Cylinder head
Cylinder head bolts - M10; 25+(60-°65°)+(60°-65°) Nm (250+[60°-65°] +[60°-65°] kg-cm, 18+[60°-65°]+[60°-65°] ft. lbs.)
Cylinder head bolts - M12; 30+(60-°65°)+(60°-65°) Nm (300+[60°-65°] + [60°-65°] kg-cm, 22+[60°-65°] +[60° 65°] ft. lbs.)
Cylinder head bolt
M10: .......................25 Nm (250kg.cm, 18 ft. lbs.)+(60°- 65°)+(60°- 65°)
M12: ..........................30 Nm (300kg.cm, 22 ft. lbs.)+(60°- 65°)+(60°- 65°)
Intake manifold nuts 18-25 Nm (180-250 kg-cm, 13-18 ft. lbs.)
Exhaust manifold nuts 43-55 Nm (430-550 kg-cm, 32-41 ft. lbs.)
Cylinder head cover bolts 8-10 Nm (80-100 kg-cm, 6-7 ft. lbs.)
Camshaft bearing cap bolts 14-15 Nm (140-150 kg-cm, 10-11 ft. lbs.)
Rear plate bolts 8-10 Nm (80-100 kg-cm, 6-7 ft. lbs.)
Adjusting Shim Selection Chart (Intake):
Adjusting Shim Selection Chart (Exhaust):
Adjusting Shim Selection Charts