Overhaul

CYLINDER HEAD ASSEMBLY (1ZZ-FE)





COMPONENTS

OVERHAUL





1. REMOVE W/HEAD TAPER SCREW PLUG NO.2
a. Using a socket hexagon wench 10, remove the taper screw plug and gasket.





2. REMOVE VALVE LIFTER
a. Remove the 16 valve lifters from the cylinder head.
3. REMOVE VALVE

HINT: Remove all the valves from the cylinder head in accordance with the procedure below.





a. Place the cylinder head on wooden blocks.
b. Using SST, compress the spring, then remove the 2 retainer locks.
SST 09202-70020 (09202-00010, 09202-01010, 09202-01020)
c. Remove the retainer, spring and valve from the cylinder head.





4. REMOVE VALVE STEM OIL 0 SEAL OR RING
a. Using needle-nose pliers, remove the 16 oil seals.





5. REMOVE VALVE SPRING SEAT
a. Using a compressed air and a magnetic finger, remove the 16 spring seats.





6. REMOVE STUD BOLT
a. Using torx socket wrenches E5 and E7, remove the 11 stud bolts.





7. CHECK CYLINDER HEAD FOR FLATNESS
a. Using a precision straight edge and a feeler gauge, measure the surface that is in contact with the cylinder block and the manifolds for warpage. Maximum warpage: 0.05 mm (0.0020 inch) for cylinder block side 0.10 mm (0.0039 inch) for intake manifold side 0.10 mm (0.0039 inch) for exhaust manifold side
If the warpage is greater than maximum, replace the cylinder head.





8. CHECK CYLINDER HEAD FOR CRACKS
a. Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.





9. INSPECT VALVE SEATS
a. Apply a light coat of Prussian blue (or white lead) to the valve face.
b. Lightly press the valve against the seat.

NOTICE: Do not turn the valve.

c. Check the valve face and seat in accordance with the following procedure.
(1) If blue appears 3600 around the face, the valve is concentric. If not, replace the valve.
(2) If blue appears 3600 around the valve seat, the guide and face are concentric. If not, resurface the seat.
(3) Check that the seat contact is in the middle of the valve face with a width of 1.0 to 1.4 mm (0.039 to 0.055 inch).
10. REPAIR INTAKE VALVE SEATS

NOTICE: Releasing the seat cutter pressure makes the valve seat faces smoother.

a. Using a 45° cutter, cut the valve face of the cylinder head a little wider than the specified valve seating width.
b. Confirm that the valve fits the valve seat center portion.
If not, re-cut the valve face with the 45° cutter.
c. Adjust the valve face with a 30° or 600 cutter so that the valve seat is in the valve seat center portion.





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





(2) If the seating is too low on the valve face, use the 600 and 45° cutters to correct the seat.
d. Lap the valve and valve seat with an abrasive compound. Do this work by hand.
e. Recheck the valve seating position.
11. REPAIR EXHAUST VALVE SEATS

NOTICE: Releasing the seat-cutter pressure gradually make the valve seat faces smoother.

a. Using the 45° cutter, cut the valve face of the cylinder head a little wider than the specified valve seating width.
b. Confirm that the valve fits the valve seat center portion.
If not, re-cut the valve face with the 45° cutter.
c. Adjust the valve face with the 30° or 75° cutter to accurately fit the valve seat center portion.





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





(2) If the seating is too low on the valve face, use the 75° and 45° cutters to correct the seat.
d. Lap the valve and valve seat with an abrasive compound. Do this work by hand.
e. Recheck the valve seating position.





12. CHECK CAMSHAFT THRUST CLEARANCE
a. Install the 2 camshafts.
b. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.
Standard thrust clearance: 0.040 to 0.095 mm (0.0016 to 0.0037 inch)
Maximum thrust clearance: 0.110 mm (0.0043 inch)
- If the thrust clearance is greater than maximum, replace the cylinder head.
- If damages are found on the camshaft thrust surfaces, replace the camshaft.





13. CHECK CAMSHAFT OIL CLEARANCE
a. Clean the 9 bearing caps and camshaft journals.
b. Place the camshafts on the cylinder head.
c. Lay a strip of Plastigage across each of the camshaft journal.
d. Install the 9 bearing caps.

NOTICE: Do not turn the camshaft.

e. Remove the 9 bearing caps.





f. Measure the Plastigage at its widest point.
Standard oil clearance: 0.035 to 0.072 mm (0.0014 to 0.0028 inch)
Maximum oil clearance: 0.10 mm (0.0039 inch)

NOTICE: Completely remove the Plastigage after measuring.

If the oil clearance is greater than maximum, replace the cylinder head or the camshaft.





14. INSPECT VALVE LIFTER
a. Using a micrometer, measure the valve lifter diameter.
Lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 inch)
If the diameter is not as specified, replace the valve lifter.





15. CHECK VALVE LIFTER OIL CLEARANCE
a. Using a caliper gauge, measure the valve lifter bore diameter of the cylinder head.
Lifter bore diameter: 31.000 to 31.025 mm (1.2205 to 1.2215 inch)
If the diameter is not as specified, replace the cylinder head.
b. Subtract the valve lifter diameter measurement from the valve lifter bore diameter measurement.
Standard oil clearance: 0.024 to 0.059 mm (0.0009 to 0.0023 inch)
Maximum oil clearance: 0.079 mm (0.0031 inch)
- If the oil clearance is greater than maximum, re-place the valve lifter.
- If necessary, replace the cylinder head.





16. INSPECT INNER COMPRESSION SPRING
a. Using vernier calipers, measure the free length of the inner compression spring.
Free length: 43.40 mm (1.7087 inch)
If the length is not as specified, replace the inner compression spring.





b. Using a steel square, measure the deviation of the inner compression spring.
Maximum deviation: 1.6 mm (0.063 inch)
Maximum angle (reference): 20
If the deviation is greater than maximum, replace the inner compression spring.





c. Using a spring tester, measure the tension of the inner compression spring at the specified installed length.
Installed tension: 158.6 to 175.4 N (16.2 to 17.9 kgf, 35.7 to 39.5 lbs) at 33.6 mm (1.323 inch)
Maximum working tension: 335.3 to 370.7 N (34.2 to 37.8 kgf, 75.4 to 83.3 lbs) at 24.1 mm (0.949 inch)
If the installed tension is not as specified, replace the inner compression spring.





17. INSPECT VALVE
a. Using vernier calipers, measure the overall valve length.




Standard overall length




Minimum overall length
If the overall length is less than minimum, replace the valve.





b. Using a micrometer, measure the diameter of the valve stem.




Valve stem diameter
If the diameter is not as specified, replace the valve.





c. Using vernier calipers, check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 inch)
Minimum margin thickness: 0.7 mm (0.028 inch)
If the margin thickness is less than minimum, replace the valve.





18. CHECK VALVE GUIDE BUSHING OIL CLEARANCE
a. Using a caliper gauge, measure the internal diameter of the valve guide bushing.
Busing inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 inch)
If the internal diameter is not as specified, replace the valve guide bushing.
b. Subtract the valve stem diameter measurement from the guide bushing internal diameter measurement.




Standard oil clearance




Maximum oil clearance
If the oil clearance is greater than maximum, replace the valve and valve guide bushing.





19. REPLACE VALVE GUIDE BUSHING
a. Heat the cylinder head up to 80 to 1OO°C (176 to 212°F).





b. Place the cylinder head on the wooden blocks.
c. Using SST, tap out the valve guide bushing.
SST 09201-10000 (09201-01050), 09201-01055, 09950-70010 (09951-07100)





d. Using a caliper gauge, measure the bushing bore diameter of the cylinder head.
Diameter: 10.285 to 10.306 mm (0.4049 to 0.4058 inch)
If the bushing bore diameter of the cylinder head is greater than 10.306 mm (0.4058 inch), machine the bushing bore to a dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 inch) to install an oversize valve guide bushing.






HINT:





e. Heat the cylinder head up to 80 to 100°C (176 to 212°F).





f. Place the cylinder head on wooden blocks.
g. Using SST, tap in a new valve guide bushing to the specified height.
SST 09201-10000 (09201-01050), 09201-01055, 09950-70010 (09951-07100)
Height: 8.7 to 9.1 mm (0.343 to 0.358 inch)





h. Using a sharp 5.5 mm reamer, ream the valve guide bushing to the standard specified clearance.




Standard oil clearance





20. INSTALL STRAIGHT PIN
a. Using a plastic hammer, install the new 2 straight pins.
Standard protrusion: 5 mm (0.197 inch)





21. INSTALL UNION
a. Mark the standard position away from the edge, onto a new union with paint.





b. Apply adhesive to the union hole of the cylinder head.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent.





c. Using a press, push in a new union until the standard marks come to the level of the cylinder head surface.




Standard protrusion

NOTICE:
- Install the union within 3 minutes of applying adhesive.
- Do not put in coolant at least for an hour after installation.

22. INSTALL STUD BOLT
a. Using torx socket wrenches E5 and E7, install the 11 stud bolts.







Torque





23. INSTALL VALVE SPRING SEAT
a. Install the 16 spring seats onto the cylinder head.





24. INSTALL VALVE STEM OIL 0 SEAL OR RING
a. Apply a light coat of engine oil to a new valve stem oil seals.

NOTICE: Be careful when assembling the oil seal of the intake and exhaust. Mixing them up may cause a failure.

HINT: The intake valve stem oil seal is gray and exhaust valve stem oil seal is black.

b. Using SST, push in the 16 oil seals by hand.
SST 09201-41020
25. INSTALL VALVE

HINT: Remove all the valves from the cylinder head according to the procedure below.





a. Place the cylinder head on wooden blocks.
b. Install the valve, spring and retainer onto the cylinder head.
c. Using SST, compress the spring, and place the 2 retainer locks around the valve stem.
SST 09202-70020 (09202-00010, 09202-01010, 09202-01020)





d. Using a pin punch 5, lightly tap the valve stem tip to ensure a proper fit.

NOTICE: Be careful not to damage the valve stem tip.





26. INSTALL VALVE LIFTER
a. Apply a light coat of engine oil to the 16 valve lifters.
b. Install the 16 valve lifters onto the cylinder head.





27. INSTALL W/HEAD TAPER SCREW PLUG NO.2
a. Using a socket hexagon wrench 10, install the taper screw plug with a new gasket.
Torque: 44 Nm (449 kgf-cm, 33 ft. lbs.)