Removal
1. Cylinder head assembly; 2. Cylinder head bolt; 3. Cylinder head gasket. See below.
Disassembly
1. Crackers; 2. Valve spring plate; 3. Valve spring (release) (with valve spring seat); 4. Valve seal; 5. Valve guide (release); 6. Valve seat (release); 7. Valve (release); 8. Valve (inlet); 9. Valve seat (inlet); 10. Cylinder head; 11. Valve guide (inlet); 12. Spark plug; 13. Valve spring (inlet) (with valve spring seat); A. See below; Q. See below.
Removal and installation
Removal
1. Relieve fuel pressure. See chapter "Engine management system".
2. Drain the engine coolant and engine oil. See chapter "Engine lubrication and cooling system".
3. Remove the following components.
- intake manifold; see above;
- intake manifold; see above;
- fuel injectors and fuel pipe assembly; see above;
- exhaust pipe; see chapter "Engine lubrication and cooling system";
- valve cover; see above;
- front timing chain cover, see above;
- camshafts; see above.
4. Remove the cylinder head.
- Loosen the mounting bolts in the reverse order shown in the illustration.
- Loosen cylinder head bolts using a TORX socket (size E18).
5. Remove the gasket from the cylinder head.
Installation
1. Place the gasket on the cylinder head.
2. Install the cylinder head and tighten the mounting bolts in the order indicated by the numbers in the figure as follows:
Attention. If reusing bolts, check their outer diameters before installation. See below.
A. Apply fresh engine oil to the threads and seating surfaces of the mounting bolts.
b. Tighten all bolts.
. 40.0 Nm (4.1 kg-m)
With. Tighten all bolts 100°clockwise (angle tightening).
Attention. Check the tightening angle with a protractor wrench (special tool: KV10112100) (A) or a protractor. Avoid assessing by eye without the use of tools.
d. Loosen completely.
0 Nm (0 kg-m).
Attention. At point «d» loosen the mounting bolts in the reverse order shown in the illustration.
e. Tighten all bolts.
40.0 Nm (4.1 kg m).
f. Tighten all bolts 100°clockwise (angle tightening).
g. Tighten all bolts an additional 100°clockwise (angle tightening).
3. After this operation, installation is performed in the reverse order of removal.
Disassembly and assembly
Disassembly
1. Remove the spark plugs using a wrench (suitable special tools).
2. Remove the valve tappets.
- Mark the locations and place the components in order without mixing them.
3. Take out the crackers.
- Compress the valve spring using a tool, attachment and adapter (special tool KV10116200) (A). Remove the crackers using a finger magnet.
Attention. When carrying out work, do not damage the hole for the valve tappets.
4. Remove the valve spring retainer and valve spring (with valve spring seat).
Attention. Do not remove the valve spring seat from the valve spring.
5. Push the valve stem towards the combustion chamber and remove the valve.
- Mark the locations and place the components in order without mixing them.
6. Remove the valve seal using a puller (special tool KV10107902) (A).
7. If the valve seat needs to be replaced.
Drill out the old seat until it breaks. Drilling should not proceed deeper than the bottom of the seat recess in the cylinder head. For this purpose, install a drill depth limiter on the drill. See section below «Technical data and specifications».
Attention. Do not scratch the cylinder head by over-drilling.
8. If you need to replace the valve guide:
A. Remove the valve guide by heating the cylinder head to 110-130°C by immersing it in hot oil (A).
b. Drive out the valve guide using a hammer and drift (suitable special tools).
Attention. The cylinder head is hot. To avoid getting burned during work, wear protective clothing.
Assembly
1. If the valve guide was removed, install it.
Attention. Replace it with a guide of increased repair size (by 0.2 mm).
A. Ream out the hole for the valve guide in the cylinder head using a reamer (suitable special tools) (A) (see fig.).
- Valve guide hole diameter (repair size increased by 0.2 mm), see section below "Technical data and specifications".
b. Heat the cylinder head to 110-130°C by immersing it in hot oil (A).
With. Press in the valve guide (1) from the camshaft side, guided by the dimensions shown in the figure.
2. Cylinder head.
Ledge «N»: See section below «Technical data and specifications».
Attention. The cylinder head is hot. To avoid getting burned during work, wear protective clothing.
d. Using a sweep (suitable special tools) (A) fine-tune the surface of the valve guide.
Standard: See section below «Technical data and specifications».
2. If the valve seat was removed, install it.
Attention. Replace it with an oversize valve seat (by 0.5 mm).
A. Ream the notch (1) in the cylinder head under a repair size valve seat.
2. Valve seat.
Diameter of the recess in the cylinder head for the valve seat (repair size increased by 0.5 mm): see section below «Technical data and specifications».
- Ream out in concentric circles toward the center of the valve guide. This will ensure the valve seat is seated correctly.
b. Heat the cylinder head to 110-130°C by immersing it in hot oil (A).
With. Cool the valve seats thoroughly with dry ice. Press the valve seats into the cylinder head.
Attention.
- Do not touch cooled saddles with bare hands.
- The cylinder head is hot. To avoid getting burned during work, wear protective clothing.
d. Bring the saddle to the required dimensions by milling or grinding using suitable special tools. See dimensions below in section «Technical data and specifications».
Attention. When processing a surface with a cutter, grasp the handle with both hands. Then press the cutter against the contact surface around the entire circumference and rout in single passes. If you press the tool unevenly or with detachment, the valve seat may take on a stepped shape.
e. Grind the valve using grinding paste.
f. Recheck valve fit. See below.
3. Press in the valve seal.
- Press in the valve seal using a drift (special tool KV10115600) (A) according to the dimensions indicated in the figure.
Note. Size «N» represents the height measured before installing the valve spring (with valve spring seat).
Height «N»: 15.1-15.7 mm.
4. Install the valve.
- Install larger diameter valves on the intake side.
5. Install valve spring (with valve spring seat).
- Install the spring side with a narrow pitch of turns (valve spring seat side) to the cylinder head (IN).
- Check the valve spring color code (A).
Inlet: green.
Issue: purple color.
1. Valve spring seat (do not remove from the valve spring).
6. Install the valve spring retainer.
7. Install the crackers.
- Compress the valve spring using a tool, attachment and adapter (special tool KV10116200) (A) (see fig.). Place the crackers using a finger magnet.
Attention. When carrying out work, do not damage the holes for the valve tappets.
- After installing the valve components to ensure proper seating, lightly tap the tip of the valve stem with a plastic hammer.
8. Install valve tappets.
- Install them in their original position.
9. Screw in the spark plugs using a wrench (suitable special tools).
Check after removal
Outer diameter of cylinder head bolts.
- The cylinder head bolts are tightened using the plastic zone method. If the difference between «d1» and «d2» exceeds the limit value, replace the bolts with new ones.
Limit «d1» - «d2»: 0.15 mm.
- If a narrowing of the outer diameter is found in a location other than «d2», designate it as a point «d2».
Cylinder head warpage
Note. When carrying out this check, you should also check whether the cylinder block is warped. See section below «Technical data and specifications».
1. Wipe off the oil and use a scraper to remove any remaining gasket, sealant and carbon deposits from the surface of the cylinder head.
Attention. Do not allow gasket residue to get into the engine oil or coolant passages.
2. Using a ruler (A) and feeler gauge (IN) Check whether the bottom surface of the cylinder head is warped by taking measurements in six directions.
Limit: See section below «Technical data and specification».
- If warpage exceeds the limit, replace the cylinder head.
Check after disassembly
Valve dimensions
- Check the sizes of all valves. See dimensions below in section «Technical data and specifications».
- If the dimensions are not normal, replace the valve and check the valve seat contact pattern.
Valve guide clearance
Valve stem diameter.
Measure the diameter of the valve stem with a micrometer (A).
Standard: See section below «Technical data and specifications».
Valve guide inner diameter.
Measure the inner diameter of the valve guide with a bore gauge.
Standard: See section below «Technical data and specifications».
Valve guide clearance.
(Valve guide clearance) - (valve guide inner diameter) - (valve stem diameter).
Standard and Limit: See section below «Technical data and specifications».
- If the obtained value exceeds the limit, replace the valve and/or valve guide. If the valve guide needs to be replaced, see section above «Disassembly and assembly».
Valve seat contact patch
- Perform this check by making sure that the dimensions of the valve guides and the valves themselves are within the specified limits.
- Apply red lead (or white lead) not the contact surface of the valve seat and check the fit of the valve to the seat.
- Make sure that the red lead imprint appears all the way around without any breaks.
A. Normal; B. Abnormal
- Otherwise, achieve the required degree of valve fit by regrinding it and check again. If the contact surface is still unsatisfactory even after re-inspection, replace the valve seat. See above.
Valve spring squareness
- Attach a corner (A) to the valve spring and rotate the spring. Measure the maximum clearance between the top of the spring and the angle.
B. Point of contact
Limit: See section below «Technical data and specifications».
- If the clearance exceeds the limit value, replace the valve spring.
Valve spring dimensions and compression force
- Check the compression force of the valve spring with the seat installed at the standard spring height.
Attention. Do not remove the valve spring seat from the valve spring.
Standard: See section below «Technical data and specifications».
- If the load after installation or with the valve open is different from the norm, replace the valve spring (with valve spring seat).
Check after installation
Leak check
- Below are procedures to check for engine oil and exhaust fluid leaks.
- Before starting the engine, check the oil/fluid levels including engine coolant and engine oil. If the level is below normal, add and bring to the required level. See chapter "Maintenance".
- Check for fuel leaks as follows. Turn the ignition key to the ON position (without starting the engine). After creating pressure in the fuel lines, check for fuel leaks at the joints. Start the engine. While increasing the engine speed, check again for fuel leaks at the fuel line joints.
- Run the engine and check for unusual noise or vibration.
- Warm up the engine thoroughly and check for leaks of fuel, exhaust gases or oil fluids including engine oil and engine coolant.
- Bleed the air from the pipes and hoses of the relevant systems, such as the cooling system.
- Once the engine has cooled, check the oil/fluid levels again, including engine oil and engine coolant. If necessary, top up and bring to the required level.
Check table
Component | Before starting the engine | Engine running | After stopping the engine |
Engine coolant | Level | Leakage | Level |
Motor oil | Level | Leakage | Level |
Other oils and liquids* | Level | Leakage | Level |
Fuel | Leakage | Leakage | Leakage |
Exhaust gases | — | Leakage | — |
* Fluid for manual transmission, automatic transmission, CVT, power steering, brake fluid, etc.