CYLINDER HEAD ASSEMBLY
Mechanical
20. Cylinder Head Assembly
S153093
12) Remove bolts (a) and (b) to remove cylinder head.
A: REMOVAL
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1)   Remove V-belt. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.>
2)   Remove crankshaft pulley. <Ref. to ME(SOHC)-44, REMOVAL, Crankshaft Pulley.>
3)   Remove belt cover. <Ref. to ME(SOHC)-45, REMOVAL, Belt Cover.>
4)   Remove timing belt assembly. <Ref. to ME(SOHC)-46, REMOVAL, Timing Belt Assem­bly. >
5)   Remove camshaft sprocket. <Ref. to ME(SOHC)-51, REMOVAL, Camshaft Sprocket.>
6)   Remove intake manifold. <Ref. to FU(SOHC)-15, REMOVAL, Intake Manifold.> or <Ref. to FU(SOHCw/oOBD)-12, REMOVAL, Intake Mani­fold.>
7)   Remove bolt which installs A/C compressor bracket on cylinder head.
8)   Remove valve rocker assembly. <Ref. to ME(SOHC)-54, REMOVAL, Valve Rocker Assem­bly. >
9)   Remove camshaft. <Ref. to ME(SOHC)-56, REMOVAL, Camshaft.>
10)   Remove cylinder head bolts in alphabetical sequence shown in figure.
CAUTION:
Leave bolts (a) and (c) engaged by three or four
threads to prevent cylinder head from falling.
13)   Remove cylinder head gasket.
CAUTION:
Do not scratch the mating surface of cylinder
head and cylinder block.
14)  Similarly, remove right side cylinder head.
B: INSTALLATION
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1)   Install cylinder head and gaskets on cylinder block.
CAUTION:
-  Use new cylinder head gaskets.
-  Be careful not to scratch the mating surface of cylinder block and cylinder head.
2)  Tighten cylinder head bolts.
(1)  Apply a coat of engine oil to washers and bolt threads.
(2)  Tighten all bolts to 29 Nm (3.0 kgf-m, 22 ft-lb) in alphabetical sequence.
Then tighten all bolts to 69 Nm (7.0 kgf-m, 51 ft-lb) in alphabetical sequence.
(3)   Back off all bolts by 180° first; back them off by 180° again.
(4)  Tighten bolts (a) and (b) to 34 Nm (3.5 kgf-m, 25 ft-lb).
(5)  Tighten bolts (c), (d), (e) and (f) to 15 Nm (1.5 kgf-m, 11 ft-lb).
(6)  Tighten all bolts by 80 to 90° in alphabetical sequence.
CAUTION:
Do not tighten bolts more than 90°.
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11) While tapping cylinder head with a plastic hammer, separate it from cylinder block.
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Mechanical
(7) Further tighten all bolts by 80 to 90° in alphabetical sequence shown in figure below.
CAUTION:
Ensure that the total "re-tightening angle" [in
the former two steps], do not exceed 180°.
C: DISASSEMBLY
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1)   Place cylinder head on ST.
ST 498267800 CYLINDER HEAD TABLE
2)  Set ST on valve spring. Compress valve spring and remove the valve spring retainer key. Remove each valve and valve spring.
ST 499718000 VALVE SPRING REMOVER
CAUTION:
-   Mark each valve to prevent confusion.
-  Use extreme care not to damage the lips of the intake valve oil seals and exhaust valve oil seals.
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3)   Install camshaft. <Ref. to ME(SOHC)-57, INSTALLATION, Camshaft.>
4)   Install valve rocker assembly. <Ref. to ME(SOHC)-54, INSTALLATION, Valve Rocker Assembly.>
5)   Install A/C compressor bracket on cylinder head.
6)   Install intake manifold. <Ref. to FU(SOHC)-17, INSTALLATION, Intake Manifold.> or <Ref. to FU(SOHCw/oOBD)-15, INSTALLATION, Intake Manifold.>
7)   Install camshaft sprocket. <Ref. to ME(SOHC)-51, INSTALLATION, Camshaft Sprocket.>
8)   Install timing belt assembly. <Ref. to ME(SOHC)-47, INSTALLATION, Timing Belt Assembly.>
9)   Install belt cover. <Ref. to ME(SOHC)-45, INSTALLATION, Belt Cover.>
10)   Install crankshaft pulley. <Ref. to ME(SOHC)-44, INSTALLATION, Crankshaft Pulley.>
11)   Install V-belt. <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.>
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Mechanical
D: ASSEMBLY
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(1)    Valve
(2)    Valve guide
(3)    Valve spring seat
(4)    Oil seal
(5)    Valve spring
(6)    Retainer
(7)    Retainer key
(8)    Spark plug gasket
(9)    Camshaft
(10)  Oil seal
(11)  Plug
(12)  Camshaft cap
(13)  Valve rocker ASSY
1) Installation of valve spring and valve
(1)   Place cylinder head on ST.
ST 498267800 CYLINDER HEAD TABLE
(2)  Coat stem of each valve with engine oil and insert valve into valve guide.
CAUTION:
When inserting valve into valve guide, use spe­cial care not to damage the oil seal lip.
(3)   Install valve spring and retainer.
CAUTION:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder
head.
(4) Set ST on valve spring. ST 499718000 VALVE SPRING REMOVER
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Mechanical
(5) Compress valve spring and fit valve spring retainer key.
CAUTION:
-  Apply engine oil to oil seal before press-fit­ting.
-  When press-fitting oil seal, do not use ham­mer or strike in.
-  Differentiate between intake valve oil seal and exhaust valve oil seal by noting their dif­ference in color.
ST1 498267800 CYLINDER HEAD TABLE ST2 498857100 VALVE OIL SEAL GUIDE
Color of rubber part: Intake [Black] Exhaust [Brown]
Color of spring part: Intake [Silver] Exhaust [Silver]
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(6) After installing, tap valve spring retainers lightly with wooden hammer for better seating.
E: INSPECTION 1. VALVE SPRING
1)  Check valve springs for damage, free length, and tension. Replace valve spring if it is not to the specifications presented below.
2)  To measure the squareness of the valve spring, stand the spring on a surface plate and measure its deflection at the top using a try square.
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Free length
54.30 mm (2.1378 in)
Squareness
2.5°, 2.4 mm (0.094 in)
Tension/spring height
218.7 - 242.5 N (22.3 - 24.7 kgf, 49.2 - 54.5 lb)/ 45.0 mm (1.772 in)
526.6 - 581.6 N (53.7 - 59.3 kgf, 118.4 - 130.8 lb)/34.7 mm (1.366 in)
F: ADJUSTMENT 1. CYLINDER HEAD
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1)   Make sure that no crack or other damage exists. In addition to visual inspection, inspect important areas by means of red lead check. Also make sure that gasket installing surface shows no trace of gas and water leaks.
2)   Place cylinder head on ST.
ST 498267800 CYLINDER HEAD TABLE
3)   Measure the warping of the cylinder head sur­face that mates with crankcase using a straight edge and thickness gauge.
If the warping exceeds 0.05 mm (0.0020 in), regrind the surface with a surface grinder.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder head: 97.5 mm (3.839 in)
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2. INTAKE AND EXHAUST VALVE OIL
SEAL
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Replace oil seal with new one, if lip is damaged or spring out of place, or when the surfaces of intake valve and valve seat are reconditioned or intake valve guide is replaced. Use pliers to pinch and remove oil seal from valve.
1)   Place cylinder head on ST1.
2)   Press-fit oil seal to the specified dimension indi­cated in the figure using ST2.
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CYLINDER HEAD ASSEMBLY
Mechanical
CAUTION:
Uneven torque for the cylinder head bolts can cause warping. When reassembling, pay spe­cial attention to the torque so as to tighten evenly.
3. VALVE GUIDE
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1) Check the clearance between valve guide and stem. The clearance can be checked by measur­ing the outside diameter of valve stem and the inside diameter of valve guide with outside and inside micrometers respectively.
Clearance between the valve guide and valve stem: Standard
Intake 0.035 - 0.062 mm (0.0014 - 0.0024 in)
Exhaust 0.040 - 0.067 mm (0.0016 - 0.0026 in) Limit
0.15 mm (0.0059 in)
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2. VALVE SEAT
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Inspect intake and exhaust valve seats, and cor­rect the contact surfaces with valve seat cutter if they are defective or when valve guides are replaced.
Valve seat width: W Intake
Standard 1.0 mm (0.039 in)
Limit 1.7 mm (0.067 in) Exhaust
Standard 1.4 mm (0.055 in)
Limit 2.1 mm (0.083 in)
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2) If the clearance between valve guide and stem exceeds the limit, replace valve guide or valve itself whichever shows greater amount of wear. See following procedure for valve guide replace­ment.
Valve guide inner diameter:
6.000 - 6.012 mm (0.2362 - 0.2367 in)
Valve stem outer diameters: Intake
5.950 - 5.965 mm (0.2343 - 0.2348 in) Exhaust
5.945 - 5.960 mm (0.2341 - 0.2346 in)
(1) Place cylinder head on ST1 with the com­bustion chamber upward so that valve guides enter the holes in ST1.
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CYLINDER HEAD ASSEMBLY
Mechanical
(2) Insert ST2 into valve guide and press it
down to remove valve guide. ST1 498267800 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER
(5) Put new valve guide, coated with sufficient
oil, in cylinder, and insert ST1 into valve guide.
Press in until the valve guide upper end is flush
with the upper surface of ST2. ST1 499767200 VALVE GUIDE REMOVER Intake side:
ST2 499767700 VALVE GUIDE ADJUSTER Exhaust side: ST2 499767800 VALVE GUIDE ADJUSTER
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(3) Turn cylinder head upside down and place
ST as shown in the figure. Intake side:
ST 499767700 VALVE GUIDE ADJUSTER Exhaust side: ST 499767800 VALVE GUIDE ADJUSTER
(6) Check the valve guide protrusion.
Valve guide protrusion: L Intake
20.0 - 20.5 mm (0.787 - 0.807 in) Exhaust
16.5 - 17.0 mm (0.650 - 0.669 in)
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(4) Before installing new oversize valve guide, make sure that neither scratches nor damages exist on the inside surface of the valve guide holes in cylinder head.
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CYLINDER HEAD ASSEMBLY
Mechanical
(7) Ream the inside of valve guide with ST. Gently rotate the reamer clockwise while press­ing it lightly into valve guide, and return it also rotating clockwise. After reaming, clean valve guide to remove chips.
CAUTION:
-  Apply engine oil to the reamer when ream­ing.
-  If the inner surface of the valve guide is torn, the edge of the reamer should be slightly ground with an oil stone.
-  If the inner surface of the valve guide becomes lustrous and the reamer does not chips, use a new reamer or remedy the reamer.
ST 499767400 VALVE GUIDE REAMER
4. INTAKE AND EXHAUST VALVE
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1) Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if "H" is less than the specified limit.
H: Intake
Standard 1.0 mm (0.039 in)
Limit 0.6 mm (0.024 in) Exhaust
Standard 1.2 mm (0.047 in)
Limit 0.6 mm (0.024 in)
Valve overall length: Intake
120.6 mm (4.75 in) Exhaust
121.7 mm (4.79 in)
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(8) Recheck the contact condition between valve and valve seat after replacing valve guide.
2) Put a small amount of grinding compound on the seat surface and lap the valve and seat sur­face. <Ref. to ME(SOHC)-64, Valve Seat, ADJUSTMENT, Cylinder Head Assembly.> Install a new intake valve oil seal after lapping.
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