Cylinder Head Assembly: Service and Repair

Cylinder Head Assembly:

Removal

1. Drain engine coolant, remove spark plugs and distributor.
2. Remove Valve cover and gasket.

Align Crank Pulley Timing Marks:

3. Turn the crankshaft and align the crank pulley timing mark with the 0 scale of the chain cover timing mark.

Check Alignment Of Cam Timing Pulley:

4. check to see that the knock pin of the camshaft flange is aligned with the embossed mark the rocker support No.1 mark, if so then valve timing is proper.

Align Cam Pulley Timing Marks:

5. If not aligned, turn the crankshaft until the flange timing pin in the camshaft is aligned with the embossed mark on the No.1 rocker support.

Check Crank Pulley Timing Marks:

6. In this position, read the graduation on the timing chain cover. If reading is 0° to 4° delayed then valve timing is good. If reading is over 4° delayed then replace the timing chain.
7. Remove the timing chain tensioner and exhaust manifold.
8. Remove the intake manifold.

Align Crank Pulley Timing Marks:

Place Matchmark On Cam Timing Pulley And Chain:

9. Set the No.1 cylinder to TDC/compression and place matchmarks on the cam timing gear and chain.

Remove Cam Timing Gear Set Bolt:

10. Remove the camshaft timing gear set bolt.

NOTE: The camshaft timing gear set bolt has left hand threads.

Cylinder Head Bolt Loosening Sequence:

11. Loosen each rocker support bolt a little at a time following the sequence as illustrated and remove.
12. Remove the rocker arm, camshaft, and bearing.
13. Remove cylinder head and gasket.

Installation






1. Clean the bolt holes with compressed air.






2. Apply the liquid sealer to the cylinder head at the points shown in the figure.






3. Tighten each cylinder head bolt a little at a time, in the sequence shown in the figure.
Tightening torque:
12 mm bolts 7.5 - 8.5 kg-m (55 - 61 ft-lb)
8 mm bolts 1.5 - 2.2 kg-m (11 - 15 ft-lb)

4. Install the timing chain.






4. Make sure the pin of the camshaft flange is in the position shown in the figure.
(1) 5M-E (USA. ARL), 5M The knock pin of the camshaft flange is aligned with embossed mark on the rocker support No.1 mark.
(2) 5M-E (ECE. Hong Kong) The knock pin of the camshaft flange is offset 3° to the left from with embossed mark on the rocker support No.1 mark.






5. Set the No. 1 cylinder to TDC compression.






6. Install the camshaft timing gear and timing chain as shown in the figure.
7. Finger tighten the camshaft timing gear.

Note: Camshaft timing gear set bolt has left hand threads.

After installing the chain tensioner, check the valve timing.






8. Turn the crankshaft in normal direction until the No.1 piston is at TDC/compression.






9. Check that the pin of the camshaft flange is in the position shown in the figure.






10. Tighten the camshaft timing gear set bolt to specified torque.
Tightening torque:
6.5 - 7.5 kg-m (48 - 54 ft-lb)

Note:The camshaft timing gear set bolt has left hand threads.

11. Adjust the valve clearance.






12. Set No cylinder to TDC/compression. At TDC/compression the rocker arms on No.1 cylinder should be loose and rockers on No.6 should be tight.






13. Adjust valve clearance.
Valve clearance is measured between valve stem and rocker arm. Adjust only the valves indicated by arrows.
Valve clearance (at cold):
IN 0.25 mm (0.0098 in.)
EX 0.33 mm (0.0130 in.)






14. Rotate crankshaft 360°. Turn the crankshaft one complete revolution and align the timing marks on the pulley. Adjust the remaining
valves as indicated by arrows

Note:After warm-up, readjust the valve clearance.

Valve clearance (at hot):
IN 0.28 mm (0.0110 in.)
EX 0.35 mm (0.0138 in.)






15. Apply the liquid sealer at the semi-circular plug shown in the figure.
16. Install the distributor