Kansas City, Missouri World Headquarters Web Auto Repair Database (WARD)

Kansas City, Missouri World Headquarters Web Auto Repair Database (WARD)

Education Division: Advanced Technology Career University (ATCU)
(Connecting Visions of Goals For The Future)

Advance Technology Career University U.S.A. Affiliates in Education
Tech Craftsman Career Building Trade School (TCCBTS)
Global Education Career Development, 501 (c) (3) Also Known As (GECD)

INDEPENDENT COMMERCIAL BUSINESS DIVISION: See ASSEMBLAGE OF RELATED SERVICES
Education Division: Advanced Technology Career University (ATCU)
(Connecting Visions of Goals For The Future)

Advance Technology Career University U.S.A. Affiliates in Education
Tech Craftsman Career Building Trade School (TCCBTS)
Global Education Career Development, 501 (c) (3) Also Known As (GECD)

INDEPENDENT COMMERCIAL BUSINESS DIVISION: See ASSEMBLAGE OF RELATED SERVICES

In order to offer Tech Craftsman Career Building Trade School's interns/apprentices more than just going to work, becasue that's what TCCBTS is all about, 24 months, working 5 days a week and 8 hours each one of those 5 day weeks, yes, its a school but learning as if it was a job.

TCCBTS's goal is to reward our first-year interns/apprentices by expending their experiences so they can show off their skill while still going to school.

How? Easy we're going to create and develop several, Independent Commercial Businesses for the interns/apprentices to work before class or after class or both, and allowed to work on weekends and paid $15.00 dollars an hour. Now the interns/apprentices are not only earning real money, but learning on the job skill social by interacting with real customers asking for their experience and help.

INDEPENDENT COMMERCIAL BUSINESS DIVISION
Review: Assemblage of Auto Related Services to better under each individual commercial businesses. Read and Review ASSEMBLAGE OF RELATED SERVICES

Business Intellectural Concept Created by James E. Grow Library of Congress Copy(c) 2015-TXu-1-954607 Certificate of Registration

To return back to Auto Tech Internship/Apprenticeship website click below: Auto Tech Internship/Apprenticeship

Cylinder Head and Related Parts

Disassembly NOTE:

  • During disassembly, be sure that the valve train components are kept together and identified so that they can be reinstalled in their original locations.
  • Before removing the cylinder head from the engine and before disassembling the valve mechanism, perform a compression test and note the results.

1. Remove camshaft drive gear pully fixing bolt (3). the pulley (4) 2. Remove camshaft bracket fixing bolt (5), camshaft bracket (6).
then camshaft exhause (7) and intake side (8).
3. Remove tapped with shim(11)

4. Use the valve spring compressor and adapter:
to remove the split collar (12). valve spring with upper seat (13)

5. Remove spark plug and valve (14)

CAUTION: Do not remove spark plugs with the head and plugs are hot. Clean dirt and debris from spark plug recess area before removal
Clean cylinder head and carefully remove all varnish, soot and carbon from the bare metal. Do not use motorized wire brush on any gasket sealing surface.

Inspection and Repair
1. Cylinder head gasket and mating surface for leaks, corrosion and blow-by. if the gasket has failed, determine the cause.

  • Insufficient torque on head bolts
  • Improper Installation
  • Warped case surface
2. Cyliner head for cracks, especially between valve seats and in the exhaust ports 3. 3.Cylinder head deck for corrosion, sand particles in head and porosity
CAUTION:
  • Do Not attempt to weld the cylinder head. Replace instead.
  • Do Not reuse cylinder head bolts
4.Cylinder head deck, common chamber and exhaust manifold mating surfaces for flatness. These surfaces may be reconditioned by milling. If the surfaces are "Out of Flat" by more than specification, the surface should be ground to within specifications. Replace the head if it requires machining beyond the repairable limit.

Head surface and manifold surface Standard: 0.05 mm (0.002 inches) or less Warpage limit: 0.2 mm (0.0079 inches)

5.Water jacket sealing plugs seating surfaces. Reassembly 1.Install Spark Plug and tighten all the spark plugs to specified torque. TORQUE: 18 N.m (1.8 Kg.m/13 lb. ft.) 2.Tighten sub gear setting bolt
  • Use spring gear spring lever to turn sub gear to right direction until the M5 bolt aligns with the hole between camshaft drive gear and sub gear.
  • Tighten the M5 bolt to a suitable torque to prevent the sub gear from moving.


3.Install camshaft drive gear assembly and tighten three bolts to the specified torque: TORQUE: 10 N.m (1.0 Kg.m/89 lb. inch) 4.Install camshaft assembly and camshaft brackets, tighten twenty bolts on one side bank to the specified torque
  • Apply engine oil to camshaft journal and bearing surface of camshaft bracket
  • Align timing mark on:
Intake camshaft (one dot for right bank, two dots for left bank) Exhaust camshaft (one dot for right bank, two dots for left bank) To timing mark on camshaft drive gear (one dot).



Standing in front of the car and starting from you left, looking at the cams you should see (RE), (RI), (LI), (LE), on each of the camshafts. (R) is for the RIGHT BANK, (L) for LEFT BANK, (I) for INTAKE and for EXHAUST. RIGHT BANK camshafts are marked with (1) DOT. LEFT BANK marked with (2) DOTS on the shaft itself To align the camshafts to each other each cam shaft gear has a mark on it. Draw an imaginary line between the center of the camshaft and the center of the pulley. The alignment mark should be between the two along this imaginary line. The result will be that (RI) and (RE) will be at the top of each gear. The same with the LEFT BANK.



Photo on left shows (Dowel Pin)

3.Tighten twenty bolts in numerical order on one side bank as shown in illustration. TORQUE: 10 N.m (1.0 Kg.m/89 lb. inches)

5.Tighten bolt for camshaft drive gear assembly pulley to the specified torque. TORQUE: 98 N.m (10.0 Kg.m/72 lb. ft.)
Valve Spring, Oil Controller, Valve, Valve Guide and Related Parts

Disassembly
1.Remove camshaft bracket fixing bolts (1).
2.Remove camshaft assembly (intake)
3.Remove camshaft assembly (Exhaust side).
4.Remove shim (4) and tapped (5)
5. Use valve spring compressor and valve spring compressor adapter to remove split collar (see drawing below)


6.Remove valve spring.
7.Remove valve.
8.Remove oil controller and spring lower seat.
9.Remove the valve guide using the 5-8840-2442-0 or equivalent


Inspection and Repair
Valve Spring CAUTION:
Visually inspect the valve springs and replace them if damaged or abnormal wear is evident.
1.Measure the free height of the spring. The springs must be replaced if the free height is below the specified limit.
Standard: 44.6 mm (1.7559 inches) Limit: 43.6 mm (1.7165 inch)


2.Measure the valve spring squareness with a steel square and replace the valve spring if the measured valve exceeds the specified limit. Limit: 2 mm (0.0787 inches)
3.using a spring tester to compress the springs to the installed height, measure the compressed spring tension, and replace the springs if the measured tension is below the specified limit. At installed height: 35.0 mm (1.38 inches) Standard: 196 N (44 lbs.) Limit: Less than 181 N (41 lbs)

Valve Guide CAUTION: Take care not to damage the valve seat contact surface, when removing carbon adhering to the valve head. Carefully inspect the valve stem for scratches or abnormal wear. If these condition are present, the valve and valve guide must be replaced as a set.
1.Measure the valve stem diameter with a micrometer. If the valve stem diameter is less than the specified limit, the valve and valve guide must be replaced as a set. Diameter of valve stem

Intake Standard: 5.97 mm - 5.959 mm (0.2353 inches -0.2346 inches) Limit: 5.90 mm (0.2323 inches)
Exhaust Standard: 5.952 mm-5.970 mm (0.2343 inches-0.2350 inches)



Grinding Valves to give clearance The New 12 exhaust valves face had to be ground 16,000th to make a tight fit Minimum clearance 10,000th


2.Measure the inside diameter of the valve guide with a micrometer. Subtract the measured outer diameter of the valve stem from the measured inner diameter of the valve guide. If the value exceeds the specified limit, the valve and the valve guide must be replaced as a set.
Inside Diameter of the valve guide Inlet clearance Standard: 0.023 mm-0.056 mm (0.0009 inches-0.0002 inches) Limit: 0.20 mm (0.00787 inches) Exhaust clearance Standard: 0.030 mm-0.063 mm (0.0012 inches-0.0025 inches) Limit: 0..20 mm (0.00787 inches)
Valve Guide Replacement 1.Using valve guide replacer tool: 5-8840-2442-0, drive out the valve guide from the combustion chamber side.



2.Apply engine oil to the outside of the valve guide. Using valve guide replacer 5-884-2442-0, drive in a new valve guide from the camshaft side, and check the valve guide height. Valve guide upper end height: 13.0 mm (0.5118 inches) (Measured from the cylinder head upper face)



3.Check the clearance is less than the specified value, ream the inside diameter of valve guide. Using a sharp 6 mm reamer, ream the valve guide to obtain the specified clearance.

Valve Seat 1.Measure the protrusion of the valve stem when a new valve is installed in the cylinder head. If the protrusion of the valve stem exceeds the limit, replace the valve seat insert or the cylinder head assembly. Protrusion of Valve Stem Intake Standard: 39.32 mm (1.5480 inches) Limit: 39.47 (1.5539 inches) Exhaust Standard: 39.30 mm (1.5472 inches) Limit: 39.45 mm (1.5531 inches)



2.Measure the valve seat contact width. Make the necessary corrections if the seat contact surface is damaged or rough or if the contact width wear exceeds the limit Valve seat contact width Standard: 1.1 mm (0.0433 inches) Limit: 1.7 mm (0.0669 inches)



Contact Surface Angle on Valve Seat on Valve 1.Measure contact surface angle on valve seat
2.If the measured value exceeds the limit, replace valve, valve guide and valve seat as a set

Valve contact surface angle: 45



Valve Seat Inset Correction 1.Remove the carbon from the valve seat insert surface.
2.Use a valve cutter to minimize scratches and other rough areas. This will bring the contact width back to the standard value. Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surface.
Valve seat angle degree: 90


3.Apply abrasive compound to the valve seat insert surface 4.Insert the valve into the valve guide 5.Trun the valve while lapping it to fit the valve seat insert. 6.Check that the valve contact width is correct. 7.Check that the valve seat insert surface is in contact with the entire circumference of the valve.


Valve Seat Insert Replacement 1.Arc weld the rod at several points. Be careful not to damage the aluminum section. 2.Allow the rod to cool for a few minutes. This will cause the valve seat to shrink. 3.Strike the rod and pull it out.


4.Carefully clean the valve seat press-fit section on the cylinder head side.
5.Heat the press-fit section with a stream or some other means to cause expansion. Cool the valve seat with dry ice or some other means.
6.Insert the press-fit section into the valve seat horizontally.

Standard fitting interference: 0.14 mm-0.09 mm (0.0055 inches-0.0035 inches)
7.After insertion, use a seat grinder to grind finish the seat face. Carefully note the seating angle, the contact width, and the depression.
8.Lap the valve and the seat.

Reassembly 1.Install valve guide (1) to cylinder head. Apply engine oil to the outside of the valve guide. Using valve guide replacer 5-8840-2442-0 tool, drive in a new valve guide from the camshaft side 2.Install oil controller (3) and spring lower seat (2). Using oil controller replacer 5-8840-0623-0 tool, drive in a new oil controller


3.Install valve to valve guide. Before install valve guide apply engine oil to the outside the valve stem 4.Install valve spring to cylinder head. attach the valve spring to the lower spring seat. The painted area of the valve spring should be facing downward.


5.Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using the 5-8840-2446-0 tool valve spring compressor and 5-8840-2547-0 tool valve spring compressor adapter to install the split collars.



  • Refer to installation procedure for camshaft in this website.

  • Valve Clearance Adjustments NOTE: To adjust valve clearance, apply engine oil to the cam as well as to the adjusting shim (2) with the cylinder head built on the cylinder block, give a few turns to the camshaft by means of timing pulley tightening bolt, and measure valve clearance with the nose of cam is just opposite to maximum cam lift (1) as shown in drawing below


    Valve Clearance Standards Value (cold)
    Intake: 0.23 mm-0.33 mm (0.0091 inches-0.0130 inches) Exhaust: 0.25 mm-0.35 mm (0.0098 inches-0.0138 inches)
    Selection of adjusting Shim Shim to be selected= (Thickness of removed shim) + (Value clearance measurement - Standard valve) Based on the above formula, the best suited shim should be selected from 41 sorts of shims (differently thick at 0.021 mm (0.0008 inches) intervals from 2.40 mm (0.0945 inches) through 3.2 mm (0.1260 inches (Thick). Install the shims and check valve clearance
    Replacement of Shim Let the cam push down the edge of tappet by using 5-8840-2444-0 tool valve clearance adjusting tool and push out the shim with a flat blade screw driver as shown in drawing below.




    Camshaft and Related Parts:


    Disassembly 1.Remove fixing bolt (5) for camshaft drive gear pulley using the 5-8840-2447-0 tool universal holder

    2.Remove twenty fixing bolts from inlet and exhaust camshaft bracket on one side bank, then camshaft bracket (2)


    3.Remove camshaft assembly (3), (4). 4.Remove three fixing bolts (7) from camshaft drive gear retainer (8), then camshaft drive gear assembly
    Inspection and Repair 1. Use a micrometer to measure the cam lob height and uneven wear. Replace the camshaft if either the lobe height or the uneven wear exceeds the specified limit. Lobe height: 44.709 mm (1.7602 inches) Uneven wear: 0.05 mm (0.0020 inch)
    2.Use a micrometer to measure the diameter and the uneven wear of the camshaft journals. Replace the camshaft if the diameter or the uneven wear exceeds the specified limit.
    Journal Diameter Standard: 25.972 mm - 25.993 mm (1.02254 inches -1.0233 inches) Limit: 25.8 mm (1.0157 inches) Uneven wear: 0.05 mm (0.0020 inches)


    3.Place the camshaft on V-blocks. Slowly rotate the camshaft and measure the runout with a dial indicator. Replace ht camshaft if the runout exceeds the specified limit
    Runout Limit: 0.1 mm (0.0039 inches)


    4.Measure the camshaft journal oil clearance.
    1.Measure the camshaft bracket housing inside diameter.
    NOTE: Tighten camshaft bracket (2) to specified torque before measuring the camshaft bracket inside diameter
    Torque: 10 N.m (1.0 Kg.m/89 lb. inches)


    2.Subtract the camshaft outside diameter from the camshaft bracket housing inside diameter.
    Oil Clearance Standard: 0.027 mm-0.078 mm (0.0011 inches-0.0031 inches) Limit: 0.11 mm (0.0043 inches)


    5.Replace the cylinder head and/or camshaft if the measured oil clearance exceeds the specified limit. 1.Carefully clean the camshaft journal, the camshaft bracket, and the cylinder head. 2.Install camshaft assembly and camshaft brackets (2), tighten twenty bolts (1) on one side bank to the specified torque.
    Torque: 10 N.m (1.0 Kg.m/89 lbl inch)


    3.Measure the camshaft thrust clearance with a dial indicator. Replace the camshaft and/or the cylinder head if the camshaft thrust clearance exceeds the specified limit.
    Camshaft thrust Clearance Standard: 0.03 mm-0.08 mm (0.0012 inches-0.0031 inches) Limit: 0.12 mm (0.0047 mm)


    Reassembly 1.Install camshaft drive gear assembly and tighten three bolts to specified torque Torque: 10 N.m (1.0 Kg.m/89 lb. inches)
    2.Tighten sub gear setting bolt. 1.Use 5-8840-2443-0 tool to turn sub gear to right direction until the M5 bolt hole aligns between camshaft driven gear and sub gear. 2.Tighten M5 bolt suitable torque for prevent moving the sub gear.


    3.Install camshaft assembly and camshaft brackets, tighten twenty bolts on one side bank to the specified torque 1.Apply engine oil to camshaft journal and bearing surface of camshaft bracket. 2.Align timing mark on intake camshaft (1 Dot for right bank, 2 Dots for left bank)
    Exhaust camshaft (1 Dot for Right Bank, 2 Dots for Left Bank) to timing mark on camshaft drive gear (1 Dot).







    3.Tighten twenty bolts in numerical order on one side bank as shown in the drawing
    Torque: 10 N.m (1.0 Kg.m/89 lb. inches)

    4.If the oil seal requires replacement, use the 5-8840-2445-0 tool to install the oil seal

    5.Tighten bolt for camshaft drive gear pulley to the specified torque using the 5-8840-2447-0 tool or universal holder
    Torque: 98 N.m (10.0 Kg.m/72 lb. ft.)