Cylinder Head Assembly: Service and Repair

CYLINDER HEAD ASSEMBLY

Part 1:

Part 2:

COMPONENT

REMOVAL
Engine removal is not required for this procedure.

CAUTION:
- Use Fender cover to avoid damaging painted surfaces.
- To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.
- When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE:
- Mark all wiring and hoses to avoid mis-connection.
- Inspect the timing belt before removing the cylinder head
- Turn the crankshaft pulley so that the No 1 piston is at top dead center.





1. Disconnect the terminals (A) from battery and remove the heat shield(B).





2. Remove the engine cover.
3. Drain the engine coolant.
4. Remove the intake air hose and air cleaner assembly.





1) Disconnect the Air Flow Sensor (AFS) connector (A).
2) Disconnect the breather hose (B) from intake air hose (D).
3) Remove the intake air hose (D) and air cleaner upper cover (c).
4) Remove the air cleaner element.





5) Remove the bolts(B) and air cleaner lower cover (A).





5. Remove the upper radiator hose (A) and lower radiator hose (B).





6. Remove the heater hoses (A).





7. Remove the accelerator cable(A) by loosening the lock - nut, then slip the cable end out of the throttle linkage.
8. Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold.





1) Disconnect the Oil Control Valve (OCV) connector (A).
2) Disconnect the oil temperature sensor connector (B).
3) Disconnect the Engine Coolant Temperature (ECT) sensor connector (c).
4) Disconnect the ignition coil connector (D).
5) Disconnect the Throttle Position Sensor (TPS) connector(A).





6) Disconnect the Idle Speed Actuator (ISA) connector (B).
7) Disconnect the Camshaft Position Sensor (CMP) connector (A).
8) Disconnect the four injector connectors (B).
9) Disconnect the knock sensor connector (c).
10) Disconnect the ground cables (D, E) from the intake manifold and vehicle's body.





11) Disconnect the air conditioner compressor switch connector(F).
12) Disconnect the front heated oxygen sensor connector(A).
13) Disconnect the Crankshaft Position Sensor (CKP) connector(B).





14) Disconnect the oil pressure switch connector(c).





15) Disconnect the Purge Control Solenoid Valve (PCSV) connector (A).
9. Disconnect the fuel inlet hose (A) of the delivery pipe side.
10. Disconnect the hose (B) of the Purge Control Solenoid Valve (PCSV) side.





11. Remove the brake booster vacuum hose(c).
12. Remove the power steering pump drive belt.
13. Remove the power steering pump and fix the pump to vehicle with a wire.





14. Remove the bolts(B, C) and power steering pump bracket(A).





15. Remove the spark plug cables.
16. Remove the exhaust manifold.
17. Remove the intake manifold.
18. Remove the timing belt.
19. Remove the PCV(Positive Crankcase Ventilation) hose.
20. Remove the cylinder head cover.
21. Remove the camshaft sprocket.





22. Insert a stopper pin or other device into timing chain auto tensioner and remove the auto tensioner.





23. Remove the camshaft bearing caps(A) and camshafts (B).





24. Remove the Oil Control Valve (OCV) (A).





25. Remove the Oil Control Valve (OCV) filter (A).





26. Remove the water hose(A) from water pipe (B).
27. Remove the cylinder head bolts, then remove the cylinder head.





1) Using 8mm and 10mm hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 cylinder head bolts and plate washers.

CAUTION: Head warpage or cracking could result from removing bolts in an incorrect order.

2) Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on wooden blocks on a bench.

CAUTION: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

DISASSEMBLY

NOTE: Identify Mechanical Lash Adjuster (MLA), valves, valve springs as they are removed so that each item can be reinstalled in its original position.





1. Remove the MLAs(A).
2. Remove the valves.





1) Using the SST (09222-28000, 09222-28100), compress the valve spring and remove the retainer lock.
2) Remove the spring retainer.
3) Remove the valve spring.
4) Remove the valve.
5) Using a needle - nose pliers, remove the oil seal.
6) Using a magnetic finger, remove the spring seat.

INSPECTION
CYLINDER HEAD





1. Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the manifolds for warpage.
Flatness of cylinder head gasket surface
Standard: Less than 0.03 mm (0.0012 inch)
Limit: 0.05 mm (0.0020 inch)
Flatness of manifold mating surface
Standard: Less than 0.15 mm (0.0059 inch)
Limit 0.30 mm (0.0118 inch)
2. Inspect for cracks. Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.

VALVE AND VALVE SPRING
1. Inspect the valve stems and valve guides.





1) Using a caliper gauge, measure the inner diameter of valve guide.
Valve guide inner diameter: 6.000 - 6.015 mm (0.2362 - 0.2368 inch)





2) Using a micrometer, measure the outer diameter of valve stem.
Valve stem outer diameter
Intake: 5.965 - 5.980 mm (0.2348 - 0.2354 inch)
Exhaust: 5.950 - 5.965 mm (0.2343 - 0.2348 inch)
3) Subtract the valve stem outer diameter measurement from the valve guide inner diameter measurement.
Valve stem - to - guide clearance
Standard
Intake: 0.020 - 0.050 mm (0.0008 - 0.0020 inch)
Exhaust: 0.035 - 0.065 mm (0.0014 - 0.0026 inch)
Limit
Intake: 0.10 mm (0.0039 inch)
Exhaust: 0.13 mm (0.0051 inch)
If the clearance is greater than maximum, replace the valve and valve guide.
2. Inspect the valves.
1) Check the valve is ground to the correct valve face angle.
2) Check the surface of the valve face for damage or wear. If the valve face is damaged or worn, replace the valve.





3) Check the valve head margin thickness. If the margin thickness is less than minimum, replace the valve.
Margin
Standard
Intake: 1.15 mm (0.0453 inch)
Exhaust: 1.35 mm (0.0531 inch)
Limit
Intake: 0.8 mm (0.0315 inch)
Exhaust: 1.0 mm (0.0394 inch)
4) Check the surface of valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect the valve seats.
1) Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
2) Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then recondition the seat.





3) Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face.
4. Inspect the valve springs.
1) Using a steel square, measure the out - of - square of valve spring.





2) Using vernier calipers, measure the free length of valve spring.
Valve spring
Standard
Free height: 48.86 mm (1.9236 inch)
Load: 18.8 ± 0.9 kg/39.0mm (41.4 ± 2.0 lbs./1.5354 inch)
41.0 ± 1.5 kg/30.5 mm (90.4 ± 3.3 lbs./1.2008 inch)
Out of square: Less than 1.5°
Limit
Out of square: 3°
If the loads is not as specified, replace the valve spring.