Cylinder Head Assembly

Cylinder Head Assembly:

VALVES:

Cylinder Head Assembly

Flatness of cylinder head surface
Standard Max. 0.03 mm (0.0012 inch)
Limit 0.1 mm (0.0039in.)

Flatness of manifold mounting surface
Standard 0.15 mm (0.0059 inch)
Limit 0.2 mm (0.008in.)

Oversize rework dimension of valve seat hole
Intake
0.3 mm (0.012 inch) O.S. 30.7 - 30.721 mm (1.2087 - 1.2095 inch)
0.6 mm (0.024 inch) O.S. 31.0 - 31.021 mm (1.2205 - 1.2213 inch)
Exhaust
0.3 mm (0.012 inch) O.S. 27.3 - 27.321 mm (1.0748 - 1.0756 in,)
0.6 mm (0.024 inch) O.S. 27.6 - 27.621 mm (1.0866 - 1.0874 inch)

Oversize rework dimensions of valve
Guide hole
0.05 mm (0.002 inch) O.S. 11.05 - 11.068 mm (0.435 - 0.4357 inch)
0.25 mm (0.010 inch) O.S. 11.25 - 11.268 mm (0.443 - 0.4436 inch)
0.50 mm (0.020 inch) O.S. 11.50 - 11.518 mm (0.453 - 0.4535 inch)

Camshaft
Cam lobe height
Intake
Standard 43.4484 mm (1.7106 inch)
Limit 42.9484 mm (1.6909 inch)
Exhaust
Standard 43.8489 mm (1.7263 inch)
Limit 43.3489 mm (1.7.66 inch)

Journal O.D o2-17 mm (1.0630 inch)
Bearing oil clearance 0.035 - 0.072 mm (0.0014 - 0.0028 inch)
End play 0.1 - 0.2 mm (0.004 - 0.008 inch)

Valve
Valve length
Intake 91.7 mm (3.6102 inch)
Exhaust 92.3 mm (3.6339 inch)

Stem 0. D.
Intake 5.955 - 5.97 mm (0.2344 - 0.2350 inch)
Exhaust 5.935 - 5.95 mm (0.2337 - 0.2343 inch)

Face angle thickness of valve head (Margin)
Intake
Standard 1.1 mm (0.0433 inch)
Limit 0.8 mm (0.031 inch)

Exhaust
Standard 1.3 mm (0.0512 inch)
Limit 1.0 mm (0.039in.)

Valve stem to valve guide clearance
Intake
Standard 0.03 - 0.06 mm (0.0012 - 0.0024 inch)
Limit 0.10 mm (0.0039in.)
Exhaust
Standard 0.05 - 0.08 mm (0.0020 - 0.0031 inch)
Limit 0.15 mm (0.0059in.)

VALVE GUIDE OVERSIZES:

Valve guide
Installed dimension O.D.
Intake 12.8 mm (0.504 inch)
Exhaust 12.8 mm (0.504 inch)

Service size 0.05, 0.25, 0.50 mm (0.002, 0.010, 0.020 inch) oversize

VALVE SEAT INSERT OVERSIZES:

Valve seat
Width of seat contact
Intake 0.8 - 1.2 mm (0.031 - 0.047 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 44.00 mm (1.7323 inch)
Load 21.6kg/ 35 mm (47.6lb/1.3780 inch) 45.1 kg/ 27.2 mm (99.4lb/1.071 inch)
Squareness 1.50 or less

Flywheel
Runout
Standard 0.1 mm (0.0039 inch)
Limit 0.13 mm (0.0051in.)

Cylinder Head Bolt Sequence:

Cylinder head bolt; 30 Nm +(90°) + Release all bolts + 30 Nm +(90°) [300 Kg.cm +(90°) + Release all bolts + 300 Kg.cm +(90°), 22 ft. lbs. +(90°) + Release all bolts + 22 ft. lbs. +(90°)]
Intake manifold bolts or nuts 15-20 Nm (150-200 kg-cm, 11-15 ft. lbs.)
Exhaust manifold nut 25 - 30 Nm (250 - 300 kg-cm, 18 - 22 ft. lbs.)
Cylinder head cover bolt 8 - 10 Nm (80 - 100 kg-cm, 6 - 7 ft. lbs.)
Camshaft bearing cap bolt 12 - 14 Nm (120 - 140 kg-cm, 9-10 ft. lbs.)
Rear plate bolt 32 - 35 Nm (320 - 350 kg-cm, 24 - 26 ft. lbs.)
Intake manifold to cylinder head nuts and bolts; 15-20 Nm (150-200 kg-cm, 11-15 ft. lbs.)
Exhaust manifold to cylinder head nuts 25-30 Nm (250-300 kg-cm, 18-22 ft. lbs.)