CYLINDER HEAD ASSEMBLY
Mechanical
19. Cylinder Head Assembly
S183093
CAUTION:
Do not scratch the mating surface of cylinder
head and cylinder block.
12) Similarly, remove right side cylinder head.
A: REMOVAL
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1)   Remove V-belt. <Ref. to ME(DOHC TURBO)-44, REMOVAL, V-belt.>
2)   Remove crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, REMOVAL, Crankshaft Pulley.>
3)   Remove belt cover. <Ref. to ME(DOHC TURBO)-47, REMOVAL, Belt Cover.>
4)   Remove timing belt assembly. <Ref. to ME(DOHC TURBO)-48, REMOVAL, Timing Belt Assembly.>
5)   Remove camshaft sprocket. <Ref. to ME(DOHC TURBO)-56, REMOVAL, Camshaft Sprocket.>
6)   Remove intake manifold. <Ref. to FU(DOHC TURBO)-15, REMOVAL, Intake Manifold.>
7)   Remove bolt which installs A/C compressor bracket on cylinder head.
8)   Remove camshaft. <Ref. to ME(DOHC TURBO)-58, REMOVAL, Camshaft.>
9)   Remove cylinder head bolts in alphabetical sequence shown in figure.
CAUTION:
Leave bolts (A) and (D) engaged by three or four threads to prevent cylinder head from fall­ing.
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 head and cylinder block.
2)  Tighten cylinder head bolts.
(1)  Apply a coat of engine oil to washers and bolt threads.
(2)  Tighten all bolts to 29 N-m (3.0 kgf-m, 22 ft-lb) in alphabetical sequence.
Then tighten all bolts to 69 N-m (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 N-m (3.5 kgf-m, 25 ft-lb).
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(5) Tighten bolts (C), (D), (E) and (F) to 15 N-m (1.5 kgf-m, 11 ft-lb).
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10) While tapping cylinder head with a plastic hammer, separate it from cylinder block. Remove bolts (A) and (D) to remove cylinder head.
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(6)  Tighten all bolts by 80 to 90° in alphabetical sequence.
CAUTION:
Do not tighten bolts more than 90°.
(7)   Further tighten all bolts by 80 to 90° in alphabetical sequence.
11) Remove cylinder head gasket.
ME(DOHC TURBO)-63
CYLINDER HEAD ASSEMBLY
Mechanical
CAUTION:
Ensure that the total "re-tightening angle" [in
the two previous steps] do not exceed 180°.
3)   Install camshaft. <Ref. to ME(DOHC TURBO)-59, INSTALLATION, Camshaft.>
4)   Install A/C compressor bracket on cylinder head.
5)   Install intake manifold. <Ref. to ME(DOHC TURBO)-59, INSTALLATION, Camshaft.>
6)   Install camshaft sprocket. <Ref. to ME(DOHC TURBO)-56,          INSTALLATION,          Camshaft Sprocket.>
7)   Install timing belt assembly. <Ref. to ME(DOHC TURBO)-49, INSTALLATION, Timing Belt Assem­bly. >
8)   Install belt cover. <Ref. to ME(DOHC TURBO)-47, INSTALLATION, Belt Cover.>
9)   Install crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, INSTALLATION, Crankshaft Pulley.>
10)   Install V-belt. <Ref. to ME(DOHC TURBO)-44, INSTALLATION, V-belt.>
C: DISASSEMBLY
S183093A06
1)   Remove valve shims and valve lifters.
2)  Compress the valve spring and remove the valve spring retainer key. Remove each valve and valve spring.
ST 498267600 CYLINDER HEAD TABLE ST 499718000 VALVE SPRING REMOVER
CAUTION:
•  Keep removed parts in order for re-installing in their original positions.
•   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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CYLINDER HEAD ASSEMBLY
Mechanical
D: ASSEMBLY
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(1)    Exhaust valve
(2)    Intake valve
(3)    Cylinder head
(4)    Valve spring seat
(5)    Intake valve oil seal
(6)    Valve spring
(7)    Retainer
(8)    Retainer key
(9)    Valve lifter
(10)  Shim
(11)  Exhaust valve oil seal
(12)  Intake valve guide
(13)  Exhaust valve guide
1) Installation of valve spring and valve
(1)  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.
(2)  Set cylinder head on ST1.
(3)  Install valve spring and retainer using ST2. ST 498267600 CYLINDER HEAD TABLE
ST 499718000 VALVE SPRING REMOVER
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CYLINDER HEAD ASSEMBLY
Mechanical
CAUTION:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder
head.
CAUTION:
Uneven torque for the cylinder head nuts can cause warping. When reassembling, pay spe­cial attention to the torque so as to tighten evenly.
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(4)  Compress valve spring and fit valve spring retainer key.
(5)  After installing, tap valve spring retainers lightly with wooden hammer for better seating.
2)  Apply oil to the surface of the valve lifter and valve shim.
3)   Install valve lifter and valve shim.
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 1.5 mm (0.059 in)
Limit 2.2 mm (0.087 in)
E: INSPECTION
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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 check.
2)   Measure the warping of the cylinder head sur­face that mates with crankcase by using a straight edge (A) and thickness gauge (B).
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:
0.3 mm (0.012 in)
Standard height of cylinder head: 127.5 mm (5.02 in)
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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.
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CYLINDER HEAD ASSEMBLY
Mechanical
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)
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.
(2)   Insert ST2 into valve guide and press it down to remove valve guide.
ST1 498267600 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER
(4)   Before installing new valve guide, make sure that neither scratches nor damages exist on the inside surface of the valve guide holes in cylinder head.
(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 ST2 498267700 VALVE GUIDE ADJUSTER
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(6)  Check the valve guide protrusion.
Valve guide protrusion: L
12.0 — 12.4 mm (0.472 — 0.488 in)
(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.
ST 499767400 VALVE GUIDE REAMER
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.
(8)   Recheck the contact condition between valve and valve seat after replacing valve guide.
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(3) Turn cylinder head upside down and place ST as shown in the figure. ST 498767700 VALVE GUIDE ADJUSTER
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CYLINDER HEAD ASSEMBLY
Mechanical
4. INTAKE AND EXHAUST VALVE
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 1.2 mm (0.047 in)
Limit 0.8 mm (0.031 in) Exhaust
Standard 1.5 mm (0.059 in)
Limit 0.8 mm (0.031 in)
Valve overall length: Intake
104.4 mm (4.110 in) Exhaust
104.7 mm (4.122 in)
5. VALVE SPRINGS
S183093A1005
1)  Check valve springs for damage, free length, and tension. Replace valve spring if it is not to the specifications presented in the table.
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.
Valve spring
Free length
44.67 mm (1.7587 in)
Tension/spring height
220.7±15.7 N (22.5±1.6 kgf, 49.6±3.5 lb)/36.0 mm (1.417 in)
510.9±25.5 N (52.1±2.6 kgf, 114.9±5.7 lb)/26.6 mm (1.047 in)
Squareness
2.5°, 2.0 mm (0.079 in)
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2) Put a small amount of grinding compound on the seat surface and lap the valve and seat sur­face. Install a new intake valve oil seal after lap­ping.
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CYLINDER HEAD ASSEMBLY
Mechanical
6. INTAKE AND EXHAUST VALVE OIL
7. VALVE LIFTER
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SEAL
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1)  Check valve lifter visually.
2)   Measure outer diameter of valve lifter.
Outer diameter:
34.959 — 34.975 mm (1.3763 — 1.3770 in)
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.
1)   Place cylinder head on ST1.
2)   Press in oil seal to the specified dimension indi­cated in the figure by using ST2.
ST1 498267600 CYLINDER HEAD TABLE ST2 498857100 VALVE GUIDE REMOVER
CAUTION:
•  Apply engine oil to oil seal before force-fit­ting.
•  Differentiate between intake valve oil seal and exhaust valve oil seal by noting their dif­ference in color.
Color of rubber part: Intake [Black] Exhaust [Brown]
Color of spring part: Intake [Silver] Exhaust [Silver]
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3) Measure inner diameter of valve lifter mating part on cylinder head.
Inner diameter:
34.994 — 35.016 mm (1.3777 — 1.3786 in)
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CAUTION:
If difference between outer diameter of valve lifter and inner diameter of valve lifter mating part is over the limit, replace cylinder head.
Standard:
0.019 — 0.057 mm (0.0007 — 0.0022 in)
Limit:
0.100 mm (0.0039 in)
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