Cylinder Head Assembly: Testing and Inspection

1. Clean top surfaces of pistons and cylinder block.





(a) Turn the crankshaft, and bring each piston to Top Dead Center (TDC).
Using a gasket scraper, remove all the carbon from the piston top surface.





(b) Using a gasket scraper, remove all the gasket material from the cylinder block surface.
(c) Using compressed air, blow carbon and oil from the bolt holes.

WARNING: Protect your eyes when using high-pressure compressed air.

2. Clean cylinder head.

3. Inspect cylinder head.





A. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage.
Maximum warpage:
Cylinder block side: 0.05 mm (0.0020 inch)
Manifold side: 0.10 mm (0.0039 inch)
If warpage is greater than maximum, replace the cylinder head.





B. Inspect for cracks.
Using a dye penetrant, check the combustion chambers, intake ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.
4. Clean valves.

5. Inspect valve stems and guide bushings.

6. If necessary, replace valve guide bushings.

7. Inspect and grind valves.

8. Inspect and clean valve seats.

9. Inspect valve springs.

10. Inspect camshafts and bearings.

11. Inspect valve lifters and lifter bores.





12. Inspect air intake chamber.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head and air intake chamber for warpage.
Maximum warpage: 0.20 mm (0.0078 inch)
If warpage is greater than maximum, replace the air intake chamber.





13. Inspect intake manifold.
Using a precision straight edge and feeler gauge, measure the surface contacting the intake manifold for warpage.
Maximum warpage: 0.20 mm (0.0078 inch)
If warpage is greater than maximum, replace the manifold.





14. Inspect exhaust manifold.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0197 inch)
If warpage is greater than maximum, replace the manifold.
15. Inspect chain tensioner.





(a) Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.





(b) Released the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
16. If necessary, replace spark plug tube gaskets.





(a) Using a screwdriver, pry out the tube gasket.





(b) Using Special Service Tool (SST) Replacer Set # 09950-60010 (Replacer 26 # 09951-00260, Replacer 49 # 09951-00490, Adapter # 09952-06010), Handle Set # 09950-70010 (Handle 150 # 09951-07150) or equivalents and hammer, tap in a new tube gasket as shown in the illustration.
(c) Apply a light coat of Multipurpose (MP) grease to the gasket lip.





17. Inspect cylinder head bolts.
Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point.
Standard outside diameter: 10.76 - 10.97 mm (0.4236 - 0.4319 inch)
Minimum outside diameter: 10.40 mm (0.4094 inch)
If the diameter is less than minimum, replace the bolt.