Cylinder Head Assembly: Testing and Inspection
2ZR-FXE ENGINE MECHANICAL: CYLINDER HEAD: INSPECTION
1. INSPECT CYLINDER HEAD FOR FLATNESS
(a) Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head contacts the cylinder block and manifold.
Text in Illustration
Maximum Warpage:
If the warpage is more than the maximum, replace the cylinder head.
2. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrate, check the intake ports, exhaust ports and cylinder surface for cracks.
If cracked, replace the cylinder head.
3. INSPECT VALVE SEATS
(a) Apply a light coat of Prussian blue to the valve face.
Text in Illustration
(b) Lightly press the valve face against the valve seat.
HINT
Do not rotate the valve while pressing the valve.
(c) Check the valve face and valve seat.
(1) Intake Side:
Check that the valve seat contacts the middle of the valve face with the width between 1.0 and 1.4 mm (0.0394 and 0.0551 in.).
If not, correct the valve seat.
(2) Exhaust Side:
Check that the valve seat contacts the middle of the valve face with the width between 1.0 and 1.4 mm (0.0394 and 0.0551 in.).
If not, correct the valve seat.
(3) Check that the contact surfaces of the valve seat and valve face are even around the entire valve seat.
If not, correct the valve seat.
4. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshafts Installation.
(b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance:
0.06 to 0.155 mm (0.00236 to 0.00610 in.)
Maximum thrust clearance:
0.17 mm (0.00669 in.)
If the thrust clearance is greater than the maximum, replace the camshaft housing. If the thrust surface is damaged, replace the camshaft.
5. INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the camshaft housing.
(c) Lay a strip of Plastigage across each of the camshaft journals.
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(d) Install the bearing caps Installation.
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps Removal.
(f) Measure the Plastigage at its widest point.
Text in Illustration
Standard Oil Clearance:
Maximum Oil Clearance:
NOTICE:
Completely remove the Plastigage after the inspection.
If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the camshaft housing.
6. INSPECT COMPRESSION SPRING
(a) Using a vernier caliper, measure the free length of the compression spring.
Standard free length:
53.36 mm (2.10 in.)
If the free length is not as specified, replace the compression spring.
(b) Using a steel square, measure the deviation of the compression spring.
Maximum deviation:
1.0 mm (0.0394 in.)
If the deviation is more than the maximum, replace the compression spring.
7. INSPECT INTAKE VALVE
(a) Using a vernier caliper, measure the overall length of the valve.
Text in Illustration
Standard overall length:
109.34 mm (4.30 in.)
Minimum overall length:
108.84 mm (4.29 in.)
If the overall length is less than the minimum, replace the valve.
(b) Using a micrometer, measure the diameter of the valve stem.
Standard valve stem diameter:
5.470 to 5.485 mm (0.215 to 0.216 in.)
If the valve stem diameter is not as specified, check the oil clearance.
(c) Using a vernier caliper, measure the valve head margin thickness.
Text in Illustration
Standard margin thickness:
1.0 mm (0.0394 in.)
Minimum margin thickness:
0.5 mm (0.0197 in.)
If the margin thickness is less than the minimum, replace the valve.
8. INSPECT EXHAUST VALVE
(a) Using a vernier caliper, measure the overall length of the valve.
Text in Illustration
Standard overall length:
108.25 mm (4.26 in.)
Minimum overall length:
107.75 mm (4.24 in.)
If the overall length is less than the minimum, replace the valve.
(b) Using a micrometer, measure the diameter of the valve stem.
Standard valve stem diameter:
5.465 to 5.480 mm (0.215 to 0.216 in.)
If the valve stem diameter is not as specified, check the oil clearance.
(c) Using a vernier caliper, measure the valve head margin thickness.
Text in Illustration
Standard margin thickness:
1.0 mm (0.0394 in.)
Minimum margin thickness:
0.5 mm (0.0197 in.)
If the margin thickness is less than the minimum, replace the valve.
9. INSPECT VALVE GUIDE BUSH OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the guide bush.
Standard bushing inside diameter:
5.510 to 5.530 mm (0.217 to 0.218 in.)
(b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.
Standard Oil Clearance:
Maximum Oil Clearance:
If the clearance is more than the maximum, replace the valve and guide bush.