Inspection
Inspection
Cylinder Head
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting cylinder block and the manifolds for warpage.
Flatness of cylinder head gasket surface
Standard : Less than 0.05mm(0.002in)
[Less than 0.02mm(0.0008in)/100x100]
Flatness of manifold gasket surface
Standard : Less than 0.1mm(0.004in)
[Less than 0.03mm(0.0012in)/110x110]
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 valve stems and valve guides.
(1) Using a caliper gauge, measure the inside diameter of the valve guide.
Valve guide I.D.
Intake / Exhaust :
6.000 - 6.012mm (0.2362 - 0.2367in)
(2) Using a micrometer, measure the diameter of the valve stem.
Valve stem O.D.
Intake : 5.965 - 5.980mm (0.2348 - 0.2354in)
Exhaust : 5.958 - 5.970mm (0.2346 - 0.2350in)
(3) Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stem-to-guide clearance
Intake : 0.020 - 0.047mm (0.0008 - 0.0018in)
Exhaust : 0.030 - 0.054mm (0.0012 - 0.0021in)
2. Inspect valves.
(1) Check the valve is ground to the correct valve face angle.
Valve face angle :
Intake/Exhaust : 45.25°~ 45.75°
(2) Check that the surface of the valve 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 minimum, replace the valve.
Margin
Intake : 1.2mm (0.0472in)
Exhaust : 1.2mm (0.0472in)
(4) Check the valve length.
Length
Intake : 107.77mm (4.2429in)
Exhaust : 107.75mm (4.2421in)
(5) Check the surface of the valve stem tip for wear.If the valve stem tip is worn, replace the valve.
3. Inspect valve seats.
(1) Check the valve seat for evidence of overheating and improper contact with the valve face.
If the valve seat is worn, replace cylinder head.
(2) Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace cylinder head.
(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.
Valve seat contact width :
Intake : 1.15 - 1.45mm (0.0453 - 0.0571in)
Exhaust : 1.35 - 1.65mm (0.0531 - 0.0650in)
Valve seat angle :
Intake/Exhaust : 44.75°~ 45.10°
4. Inspect valve springs.
(1) Using a steel square, measure the out-of-square of the valve spring.
(2) Using vernier calipers, measure the free length of the valve spring.
Valve spring
Free height : 47.8mm (1.8819in)
Out-of-square : 1.5°
Camshaft
1. Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
Intake : 41.6mm (16.4in)
Exhaust : 41.5mm (16.3in)
If the cam lobe height is less than standard, replace the camshaft.
2. Inspect the camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journals.
(4) Install the bearing cap (A) and thrust bearing cap (B) with specified torque.
Tightening torque :
1st step :
6.9 - 7.8N.m ( 0.7 - 0.8kgf.m, 5.1 - 5.8lb-ft)
2nd step :
13.7 - 14.7N.m (1.4 - 1.5kgf.m, 10.1 - 10.8lb-ft)
NOTE:
Do not turn the camshaft.
[LH]
[RH]
(5) Remove the bearing caps.
(6) Measure the plastigage at its widest point.
Camshaft bearing oil clearance
Intake/Exhaust :
No.1 journal :
0.025 - 0.057mm (0.0010 - 0.0022in)
No.2, 3, 4, 5 journal :
0.020 - 0.057mm (0.0008 - 0.0022in)
Camshaft journal outer diameter
Intake/Exhaust :
No.1 journal :
35.964 - 35.980mm (1.4159 - 1.4165in)
No.2, 3, 4, 5 journal :
25.964 - 25.980mm (1.0222 - 1.0228in)
Camshaft journal bore inner diameter
Intake/Exhaust :
No.1 journal :
36.005 - 36.021mm (1.4175 - 1.4181in)
No.2, 3, 4, 5 journal :
26.000 - 26.021mm (1.0236 - 1.0244in)
If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(7) Completely remove the plastigage.
(8) Remove the camshafts.
3. Inspect the camshaft end play.
(1) Install the camshafts.
(2) Install the bearing cap (A) and thrust bearing cap (B) with specified torque.
Tightening torque :
1st step :
6.9 - 7.8N.m ( 0.7 - 0.8kgf.m, 5.1 - 5.8lb-ft)
2nd step :
13.7 - 14.7N.m (1.4 - 1.5kgf.m, 10.1 - 10.8lb-ft)
(3) Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play :
RH-In : 0.12 - 0.22mm (0.0047 - 0.0086in)
RH-Ex, LH-In, LH-Ex :
0.1 - 0.2mm (0.0039 - 0.0079in)
If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(4) Remove the camshafts.
CVVT Assembly
1. Inspect the CVVT assembly.
(1) Check that the CVVT assembly will not turn.
(2) Apply vinyl tape to the retard hole except the one indicated by the arrow in the illustration.
(3) Apply vinyl tape to the advance hold except the one indicated by the arrow in the illustration.
(4) Wrap tape around the tip of the air gun and apply air of approx. 150kpa(1.5kgf/cm2, 21psi) to the port of the camshaft. (Perform this in order to release the lock pin for the maximum default angle locking.)
In-default :Max retard
Ex-default :Max advance
NOTE:
When the oil splashes, wipe it off with a shop rag.
(5) Under the condition of (3), turn the In-CVVT assembly to the advance angle side (the arrow marked direction in the illustration) with your hand.
Depending on the air pressure, the In-CVVT assembly will turn to the advance side without applying force by hand.
Under the condition of (3), turn the Ex-CVVT assembly to the retard angle side (the arrow marked direction in the illustration) with your hand.
Depending on the air pressure, the Ex-CVVT assembly will turn to the retard side without applying force by hand.
(6) Except the position where the lock pin meets at the maximum default angle, let the CVVT assembly turn back and forth and check the movable range and that there is no interference.
Standard :
Movable smoothly in the range about 45°
(7) Turn the In-CVVT assembly with your hand and lock it at the maximum retard angle position (clockwise).
Turn the Ex-CVVT assembly with your hand and lock it at the maximum advance angle position.
HLA (Hydraulic Lash Adjuster)
With the HLA filled with engine oil, hold A and press B by hand. If B moves, replace the HLA.
