Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting cylinder block and the manifolds for warpage.
Flatness of cylinder head gasket surface
Standard : Less than 0.05mm(0.002in)
[Less than 0.02mm(0.0008in)/100x100]
Flatness of manifold gasket surface
Standard : Less than 0.1mm(0.004in)
[Less than 0.03mm(0.0012in)/110x110]
Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.
Inspect valve stems and valve guides.
Using a caliper gauge, measure the inside diameter of the valve guide.
Valve guide I.D.
Intake / Exhaust :
6.000 ~ 6.012mm (0.2362 ~ 0.2367in)
Using a micrometer, measure the diameter of the valve stem.
Valve stem O.D.
Intake : 5.965 ~ 5.980mm (0.2348 ~ 0.2354in)
Exhaust : 5.958 ~ 5.970mm (0.2346 ~ 0.2350in)
Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stem-to-guide clearance
Intake : 0.020 ~ 0.047mm (0.0008 ~ 0.0018in)
Exhaust : 0.030 ~ 0.054mm (0.0012 ~ 0.0021in)
Inspect valves.
Check the valve is ground to the correct valve face angle.
Valve face angle :
Intake/Exhaust : 45.25˚~ 45.75˚
Check that the surface of the valve for wear. If the valve face is worn, replace the valve.
Check the valve head margin thickness. If the margin thickness is less than minimum, replace the valve.
Margin
Intake : 1.2mm (0.0472in)
Exhaust : 1.2mm (0.0472in)
Check the valve length.
Length
Intake : 107.77mm (4.2429in)
Exhaust : 107.75mm (4.2421in)
Check the surface of the valve stem tip for wear.If the valve stem tip is worn, replace the valve.
Inspect valve seats.
Check the valve seat for evidence of overheating and improper contact with the valve face.
If the valve seat is worn, replace cylinder head.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace cylinder head.
Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face.
Valve seat contact width :
Intake : 1.15 ~ 1.45mm (0.0453 ~ 0.0571in)
Exhaust : 1.35 ~ 1.65mm (0.0531 ~ 0.0650in)
Valve seat angle :
Intake/Exhaust : 44.75˚~ 45.10˚
Inspect valve springs.
Using a steel square, measure the out-of-square of the valve spring.
Using vernier calipers, measure the free length of the valve spring.
Valve spring
Free height : 47.8mm (1.8819in)
Out-of-square : 1.5˚
Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
Intake : 41.6mm (16.4in)
Exhaust : 41.5mm (16.3in)
If the cam lobe height is less than standard, replace the camshaft.
Inspect the camshaft journal clearance.
Clean the bearing caps and camshaft journals.
Place the camshafts on the cylinder head.
Lay a strip of plastigage across each of the camshaft journals.
Install the bearing cap (A) and thrust bearing cap (B) with specified torque.
Tightening torque :
1st step :
6.9 ~ 7.8N.m ( 0.7 ~ 0.8kgf.m, 5.1 ~ 5.8lb-ft)
2nd step :
13.7 ~ 14.7N.m (1.4 ~ 1.5kgf.m, 10.1 ~ 10.8lb-ft)
Do not turn the camshaft.
Remove the bearing caps.
Measure the plastigage at its widest point.
Camshaft bearing oil clearance
Intake/Exhaust :
No.1 journal :
0.025 ~ 0.057mm (0.0010 ~ 0.0022in)
No.2, 3, 4, 5 journal :
0.020 ~ 0.057mm (0.0008 ~ 0.0022in)
Camshaft journal outer diameter
Intake/Exhaust :
No.1 journal :
35.964 ~ 35.980mm (1.4159 ~ 1.4165in)
No.2, 3, 4, 5 journal :
25.964 ~ 25.980mm (1.0222 ~ 1.0228in)
Camshaft journal bore inner diameter
Intake/Exhaust :
No.1 journal :
36.005 ~ 36.021mm (1.4175 ~ 1.4181in)
No.2, 3, 4, 5 journal :
26.000 ~ 26.021mm (1.0236 ~ 1.0244in)
If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
Completely remove the plastigage.
Remove the camshafts.
Inspect the camshaft end play.
Install the camshafts.
Install the bearing cap (A) and thrust bearing cap (B) with specified torque.
Tightening torque :
1st step :
6.9 ~ 7.8N.m ( 0.7 ~ 0.8kgf.m, 5.1 ~ 5.8lb-ft)
2nd step :
13.7 ~ 14.7N.m (1.4 ~ 1.5kgf.m, 10.1 ~ 10.8lb-ft)
Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play :
RH-In : 0.12 ~ 0.22mm (0.0047 ~ 0.0086in)
RH-Ex, LH-In, LH-Ex :
0.1 ~ 0.2mm (0.0039 ~ 0.0079in)
If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
Remove the camshafts.
Inspect the CVVT for smooth rotation.
Clamp the camshaft using a vise. Be careful not to damage the cam lobes and journals in the vise.
Check that the CVVT is locked by turning it clockwise or counterclockwise. It must not rotate.
Intake CVVT : Seal one of the two advance holes in the camshaft journal with tape.
Exhaust CVVT : Seal one of the two retard holes in the camshaft journal with tape.
Intake CVVT : Apply approx. 150 kPa (1.5 kgf/㎠, 21 psi ) of compressed air into the unsealed advance hole to release the lock.
Exhaust CVVT : Apply approx. 150 kPa (1.5 kgf/㎠, 21 psi ) of compressed air into the unsealed retard hole to release the lock.
Cover the oil paths with a piece of cloth when applying compressed air to prevent oil from spraying.
Intake CVVT : With compressed air applied, rotate the CVVT into the advance direction (counterclockwise) within its phasing range and check that the CVVT turns smoothly.
Exhaust CVVT : With compressed air applied, rotate the CVVT into the retard direction (clockwise) and check that the CVVT turns smoothly.
CVVT phasing range
Intake : 22.5˚±1˚ (from the most retarded position to the most advanced position)
Exhaust : 22.5˚±1˚ (from the most advanced position to the most retarded position)
Intake CVVT : Rotate the CVVT into the most retarded position (clockwise) and then check that the CVVT is locked.
Exhaust CVVT : Rotate the CVVT into the most advanced position (counterclockwise) and then check that the CVVT is locked.
With the HLA filled with engine oil, hold A and press B by hand. If B moves, replace the HLA.
Problem | Possible cause | Action |
1. Temporary noise when starting a cold engine | Normal | This noise will disappear after the oil in the engine reaches the normal pressure. |
2. Continuous noise when the engine is started after parking more than 48 hours. | Oil leakage of the high pressure chamber on the HLA, allowing air to get in. | Noise will disappear within 15 minutes when engine runs at 2000-3000 rpm.If it doesn’t disappear, refer to step 7 below. |
3. Continuous noise when the engine is first started after rebuilding cylinder head. | Insufficient oil in cylinder head oil gallery. | |
4. Continuous noise when the engine is started after excessively cranking the engine by the starter motor or band. | Oil leakage of the high-pressure chamber in the HLA, allowing air to get in.Insufficient oil in the HLA. | |
5. Continuous noise when the engine is running after changing the HLA. | caution Do not run engine at a speed higher than 3000 rpm, as this may damage the HLA. | |
6. Continuous noise during idle after high engine speed. | Engine oil level too high or too low. | Check oil level.Drain or add oil as necessary. |
Excessive amount of air in the oil at high engine speed. | Check oil supply system. | |
Deteriorated oil. | Check oil quality.If deteriorated, replace with specified type. | |
7. Noise continues for more than 15 minutes. | Low oil pressure. | Check oil pressure and oil supply system of each part of engine. |
Faulty HLA. | Remove the cylinder head cover and press HLA down by hand.If it moves, replace the HLA. warning Be careful with the hot HLAS. |
