Cylinder Head

CYLINDER HEAD ASSEMBLY (2GR-FE)

COMPONENTS

OVERHAUL
1. REMOVE VALVE STEM CAP
a. Remove the valve stem caps from the cylinder head.

HINT: Arrange the removed parts in the correct order.

2. REMOVE INTAKE VALVE
a. Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.
SST 09202-70020 (09202-00010)
b. Remove the retainer, compression spring, and valve.

HINT: Arrange the removed parts in the correct order.

3. REMOVE EXHAUST VALVE
a. Using SST and wooden blocks, compress the compression spring and remove the valve retainer locks.
SST 09202-70020 (09202-00010)
b. Remove the retainer, compression spring, and valve.

HINT: Arrange the removed parts in the correct order.

4. REMOVE VALVE STEM OIL SEAL
a. Using needle-nose pliers, remove the oil seals.

5. REMOVE VALVE SPRING SEAT
a. Using compressed air and a magnetic finger, remove the valve spring seat by blowing air onto it.

6. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.1
a. Using a 10 mm hexagon wrench, remove the 4 screw plugs and 4 gaskets.

NOTICE: If water leaks from the w/ head straight screw plug No.1 or the plug is corroded, replace it.

7. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.2
a. Using a 14 mm hexagon wrench, remove the 2 screw plug and 2 gaskets.

NOTICE: If water leaks from the w/ head straight screw plug No.2 or the plug is corroded, replace it.

8. REMOVE RING PIN

NOTICE: It is not necessary to remove the ring pin unless it is being replaced.

9. REMOVE STUD BOLT

NOTICE: If the stud bolt is deformed or the threads are damaged, replace it.

10. INSPECT CYLINDER HEAD SUB-ASSEMBLY
a. Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder block and manifolds.
Standard warpage:
0.05 mm (0.0020 inch) for cylinder head lower
0.08 mm (0.0031 inch) for intake
0.08 mm (0.0031 inch) for exhaust
Maximum warpage: 0.10 mm (0.0039 inch)
If the warpage is greater than the maximum, replace the cylinder head.

b. Using a dye penetrate, check the intake ports, exhaust ports and cylinder surface for cracks.
If cracked, replace the cylinder head.
11. INSPECT INTAKE VALVE

a. Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 inch)

b. Using vernier calipers, measure the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.0394 inch)
Minimum margin thickness: 0.5 mm (0.0197 inch)
If the margin thickness than the minimum, replace the intake valve.

c. Using vernier calipers, measure the valve's overall length.
Standard overall length: 105.85 mm (4.1673 inch)
Minimum overall length: 105.35 mm (4.1476 inch)
If the overall length than the minimum, replace the intake valve.
12. INSPECT EXHAUST VALVE

a. Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter: 5.465 to 5.480 mm (0.2151 to 0.2157 inch)

c. Using vernier calipers, measure the valve's overall length.
Standard overall length: 110.40 mm (4.3464 inch)
Minimum overall length: 109.90 mm (4.3268 inch)
If the overall length than the minimum, replace the exhaust valve.

13. INSPECT INTAKE VALVE SEATS
a. Apply a light coat of prussian blue (or white lead) to the valve face.
b. Lightly press the valve face against the valve seat.
c. Check the valve face and valve seat by using the following procedure.
1. If prussian blue appears around the entire valve face, the valve face is concentric. 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 in the middle of the valve face with the width between 1.1 and 1.5 mm (0.043 and 0.059 inch).

14. INSPECT EXHAUST VALVE SEATS
a. Apply a light coat of prussian blue (or white lead) to the valve face.
b. Lightly press the valve face against the valve seat.
c. Check the valve face and valve seat by using the following procedure.
1. If prussian blue appears around the entire valve face, the valve face is concentric. 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 in the middle of the valve face with the width between 1.1 and 1.5 mm (0.043 and 0.059 inch).
15. REPAIR INTAKE VALVE SEATS

NOTICE: Keep the lip free from foreign matter.

a. If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.

b. If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.
c. Hand rub the valve and valve seat with an abrasive compound.
d. Check the valve seating position.
16. REPAIR EXHAUST VALVE SEATS

NOTICE: Keep the lip free from foreign matter.

a. If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.

b. If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat.
c. Hand rub the valve and valve seat with an abrasive compound.
d. Check the valve seating position.
17. INSPECT INNER COMPRESSION SPRING

a. Using vernier calipers, measure the free length of the inner compression spring.
Free length: 45.46 mm (1.7898 inch)
If the free length is not as specified, replace the spring.

b. Using a steel square, measure the deviation of the inner compression spring.
Maximum deviation: 1.0 mm (0.039 inch)
Maximum angle (reference): 2°
If the deviation is greater than the maximum, replace the spring.

18. INSPECT VALVE GUIDE BUSH OIL CLEARANCE
a. Using a caliper gauge, measure the inside diameter of the guide bush.
Bush inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 inch)
b. Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.

Standard oil clearance

Maximum oil clearance

HINT:
- If the clearance is greater than the maximum, replace the intake valve and intake guide bush (see steps 19 and 21).
- If the clearance is greater than the maximum, replace the exhaust valve and exhaust guide bush (see steps 20 and 22).

19. REMOVE INTAKE VALVE GUIDE BUSH
a. Heat the cylinder head to 80 to 100°C (176 to 212°F).
b. Place the cylinder head on wooden blocks.
c. Using SST and a hammer, tap out the guide bush.
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)

20. REMOVE EXHAUST VALVE GUIDE BUSH
a. Heat the cylinder head to 80 to 100°C (176 to 212°F).
b. Place the cylinder head on wooden blocks.
c. Using SST and a hammer, tap out the guide bush.
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)

21. INSTALL INTAKE VALVE GUIDE BUSH
a. Using a caliper gauge, measure the bush bore diameter of the cylinder head.
Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 inch)

b. Select a new guide bush (STD or O/S 0.05).
If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 inch), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 inch) to install a O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 inch), replace the cylinder head.
c. Heat the cylinder head to 80 to 100°C (176 to 212°F).

d. Place the cylinder head on wooden blocks.
e. Using SST, tap in a new valve guide bush to the specified protrusion height.
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)
Protrusion height: 9.30 to 9.70 mm (0.3661 to 0.3819 inch)

f. Using a sharp 5.5 mm reamer, ream the valve guide bush to obtain the standard specified clearance.
Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0023 inch)

22. INSTALL EXHAUST VALVE GUIDE BUSH
a. Using a caliper gauge, measure the bush bore diameter of the cylinder head.
Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 inch)

b. Select a new guide bush (STD or O/S 0.05).
If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 inch), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 inch) to install a O/S 0.05 valve guide bush.
If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 inch), replace the cylinder head.
c. Heat the cylinder head to 80 to 100°C (176 to 212°F).

f. Using a sharp 5.5 mm reamer, ream the valve guide bushing to obtain the standard specified clearance.
Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 inch)

23. INSPECT CAMSHAFT THRUST CLEARANCE
a. Install the RH bank camshafts.
b. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)
Maximum thrust clearance: 0.15 mm (0.006 inch)
If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.
c. Install the LH bank camshafts.
d. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)
Maximum thrust clearance: 0.15 mm (0.006 inch)
If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft.

24. INSPECT CAMSHAFT OIL CLEARANCE
a. Clean the bearing caps, camshaft housing and camshaft journals.
b. Place the camshafts on the camshaft housing.
c. Lay a strip of Plastigage across each of the camshaft journals.
d. Install the bearing caps.

NOTICE: Do not turn the camshaft.

e. Remove the bearing caps.

f. Measure the Plastigage at its widest point.

Standard oil clearance

Maximum oil clearance
If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.

g. Clean the bearing caps, camshaft housing and camshaft journals.
h. Place the camshafts on the camshaft housing.

i. Lay a strip of Plastigage across each of the camshaft journals.
j. Install the bearing caps.

NOTICE: Do not turn the camshaft.

k. Remove the bearing caps.

l. Measure the Plastigage at its widest point.

Standard oil clearance

Maximum oil clearance
If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.

25. INSTALL STUD BOLT

NOTICE: If the stud bolt is deformed or the threads are damaged, replace it.

a. Using E6 and E8 Torx socket wrenches, install the stud bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.) for A and B bolts
Torque: 4.0 Nm (41 kgf-cm, 35 inch lbs.) for C bolt

26. INSTALL RING PIN

a. Using a plastic hammer, tap in 4 new ring pins to the specified protrusion height.
Specified protrusion height: 2.5 to 3.5 mm (0.098 to 0.138 inch)

27. INSTALL W/HEAD STRAIGHT SCREW PLUG NO.1
a. Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)

28. INSTALL W/HEAD STRAIGHT SCREW PLUG NO.2
a. Using a 14 mm hexagon wrench, install 2 new gaskets and the straight 2 screw plugs.
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)

29. INSTALL STRAIGHT PIN
a. Using a plastic hammer, tap in 4 new straight pins as shown in the illustration.
Specified protrusion height: 17.5 to 19.5 mm (0.69 to 0.77 inch)
30. INSTALL VALVE SPRING SEAT
a. Install the valve spring seats to the cylinder head.

31. INSTALL VALVE STEM OIL SEAL
a. Apply a light coat of engine oil to new oil seals.

NOTICE: Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.

HINT: The intake valve oil seals are white and the exhaust valve oil seals are black.

b. Using SST, push in the oil seals.
SST 09201-41020

NOTICE: Failure to use SST will cause the seal to be damaged or improperly seated.

32. INSTALL INTAKE VALVE

a. Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.
b. Install the valve, compression spring and spring retainer to the cylinder head.

NOTICE: Install the same parts in the same combination to the original locations.

c. Using SST and wooden blocks, compress the spring and install the 2 retainer locks.
SST 09202-70020 (09202-00010)

d. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE: Be careful not to damage the retainer.

33. INSTALL EXHAUST VALVE
a. Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.
b. Install the valve, compression spring and spring retainer to the cylinder head.

NOTICE: Install the same parts in the same combination to the original locations.

c. Using SST and wooden blocks, compress the spring and install the 2 retainer locks.
SST 09202-70020 (09202-00010)

d. Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE: Be careful not to damage the retainer.

34. INSTALL VALVE STEM CAP
a. Apply a light coat of engine oil to the valve stem caps.
b. Install the valve stem caps to the cylinder head.