Cylinder Head Assembly: Testing and Inspection

2TR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSPECTION

1. INSPECT CYLINDER HEAD SUB-ASSEMBLY

(a) Using a precision straightedge and feeler gauge, measure the warpage of the surfaces that contact the cylinder block and manifolds.

Maximum warpage:

0.05 mm (0.00197 in.)

(b) If the warpage is more than the maximum, replace the cylinder head.

(c) Using a dye penetrant, check the intake ports, exhaust ports and cylinder head surface for cracks.

If cracked, replace the cylinder head.

2. INSPECT INNER COMPRESSION SPRING

(a) Using a vernier caliper, measure the free length of the inner compression spring.

Standard free length:

48.53 mm (1.91 in.)

(b) If the free length is not as specified, replace the spring.

(c) Using a steel square, measure the deviation of the inner compression spring.

Maximum deviation:

1.5 mm (0.0591 in.)

Maximum angle:

2°

(d) If the deviation is more than the maximum, replace the spring.

3. INSPECT INTAKE VALVE

(a) Using a vernier caliper, measure the overall length of the valve.

Standard overall length:

106.26 mm (4.18 in.)

Minimum overall length:

105.96 mm (4.17 in.)

(b) If the overall length is less than the minimum, replace the intake valve.

(c) 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.)

(d) Using a vernier caliper, measure the valve head margin thickness.

Standard margin thickness:

1.05 to 1.45 mm (0.0413 to 0.0571 in.)

Minimum margin thickness:

0.50 mm (0.0197 in.)

(e) If the margin thickness is less than the minimum, replace the intake valve.

4. INSPECT EXHAUST VALVE

(a) Using a vernier caliper, measure the overall length of the valve.

Standard overall length:

106.74 mm (4.20 in.)

Minimum overall length:

106.44 mm (4.19 in.)

(b) If the overall length is less than the minimum, replace the exhaust valve.

(c) 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.)

(d) Using a vernier caliper, measure the valve head margin thickness.

Standard margin thickness:

1.2 to 1.6 mm (0.0472 to 0.0630 in.)

Minimum margin thickness:

0.50 mm (0.0197 in.)

(e) If the margin thickness is less than the minimum, replace the exhaust valve.

5. INSPECT VALVE SEAT

(a) Apply a light coat of Prussian blue to the valve face.

(b) Lightly press the valve face against the valve seat.

HINT
Do not rotate the valve while pressing the valve against the valve seat.

(c) Check the valve face and valve seat by using the following procedure.

(1) Check that Prussian blue appears around the entire valve face. If not, replace the valve.

(2) If Prussian blue appears around the entire valve seat, the guide and valve face are concentric. If not, resurface the valve seat.

(3) Check that the valve seat contacts the middle of the valve face with the width between 1.1 and 1.4 mm (0.0433 and 0.0551 in.).

6. 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:

0.10 to 0.24 mm (0.00394 to 0.00945 in.)

Maximum thrust clearance:

0.26 mm (0.0102 in.)

(c) If the thrust clearance is more than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

7. INSPECT CAMSHAFT OIL CLEARANCE

(a) Clean the bearing caps and camshaft journals.

(b) Place the camshafts on the cylinder head.

(c) Lay a strip of Plastigage across each of the camshaft journals.

(d) Install the bearing caps Installation.

NOTICE:
Do not turn the camshafts.

(e) Remove the bearing caps Removal.

(f) Measure the Plastigage at its widest point.

Standard Oil Clearance:

Maximum oil clearance:

0.08 mm (0.00315 in.)

(g) If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the cylinder head sub-assembly.

(h) Completely remove the Plastigage.

8. INSPECT VALVE GUIDE BUSH OIL CLEARANCE

(a) Using a caliper gauge, measure the inside diameter of the guide bush.

Standard bush inside diameter:

5.51 to 5.53 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: