7GR-FKS ENGINE MECHANICAL  CYLINDER HEAD  INSPECTION  

Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head sub-assembly contacts the cylinder block sub-assembly and manifolds.

3.853,0.072 4.120,0.346 0.267,0.274 10 *a 0.238,1.711 0.505,1.985 0.267,0.274 10 *b 3.825,1.711 4.092,1.985 0.267,0.274 10 *c

*a	Intake Side	*b	Cylinder Block Side
*c	Exhaust Side	-	-

Standard Warpage:

Item	Specified Condition
Cylinder Block Side	0 to 0.05 mm (0 to 0.00197 in.)
Exhaust Side	0 to 0.08 mm (0 to 0.00315 in.)
Intake Side	0 to 0.08 mm (0 to 0.00315 in.)

Maximum warpage:

0.10 mm (0.00394 in.)

If the warpage is more than the maximum, replace the cylinder head sub-assembly.

Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks.

HINT:

If cracked, replace the cylinder head sub-assembly.

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

Standard Valve Stem Diameter:

5.470 to 5.485 mm (0.215 to 0.216 in.)

HINT:

If the valve stem diameter is not as specified, check the intake valve guide bush oil clearance.

0.344,1.792 0.656,1.948 0.313,0.156 10 false *a

*a	Margin Thickness

Using a vernier caliper, measure the valve head margin thickness.

Standard Margin Thickness:

1.0 mm (0.0394 in.)

Minimum Margin Thickness:

0.5 mm (0.0197 in.)

HINT:

If the margin thickness is less than the minimum, replace the intake valve.

1.958,0.979 2.271,1.135 0.313,0.156 10 false *a

*a	Overall Length

Using a vernier caliper, measure the overall length of the intake valve.

Standard Overall Length:

105.85 mm (4.17 in.)

Minimum Overall Length:

105.35 mm (4.15 in.)

HINT:

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

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

Standard Valve Stem Diameter:

5.465 to 5.480 mm (0.215 to 0.216 in.)

HINT:

If the valve stem diameter is not as specified, check the exhaust valve guide bush oil clearance.

0.375,1.729 0.688,1.885 0.313,0.156 10 false *a

*a	Margin Thickness

Using a vernier caliper, measure the valve head margin thickness.

Standard Margin Thickness:

1.0 mm (0.0394 in.)

Minimum Margin Thickness:

0.5 mm (0.0197 in.)

HINT:

If the margin thickness is less than the minimum, replace the exhaust valve.

1.969,1.01 2.281,1.167 0.313,0.156 10 false *a

*a	Overall Length

Using a vernier caliper, measure the overall length of the exhaust valve.

Standard Overall Length:

110.40 mm (4.35 in.)

Minimum Overall Length:

109.90 mm (4.33 in.)

HINT:

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

1.427,1.031 1.74,1.188 0.313,0.156 10 false *a

*a

Width

Check the valve face and intake valve seat by using the following procedure:

1.417,1.052 1.729,1.208 0.313,0.156 10 false *a

*a

Width

Check the valve face and exhaust valve seat by using the following procedure:

Using a vernier caliper, measure the free length of the inner compression spring.

Standard Free Length:

54.53 mm (2.15 in.)

Minimum Free Length:

52.43 mm (2.06 in.)

HINT:

If the free length is less than the minimum, replace the inner compression spring.

1.823,0 2.135,0.156 0.313,0.156 10 false *a 0.927,1.25 1.24,1.406 0.313,0.156 10 false *b

*a	Deviation
*b	40 mm (1.57 in.)

Using a steel square, measure the deviation of the inner compression spring.

Maximum Deviation (Reference):

1.4 mm (0.0551 in.)

HINT:

If the deviation is more than the maximum, replace the inner compression spring.

Using a caliper gauge, measure the inside diameter of the valve guide bush.

Standard Valve Guide Bush Inside Diameter:

5.510 to 5.530 mm (0.217 to 0.218 in.)

Inspect the camshaft thrust clearance (for Bank 1).

iii.

Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

Standard thrust clearance:

0.08 to 0.13 mm (0.00315 to 0.00512 in.)

Maximum thrust clearance:

0.15 mm (0.00591 in.)

HINT:

·

If the thrust clearance is more than the maximum, replace the camshaft housing sub-assembly.

·

If the thrust surface is damaged, replace the camshaft or No. 2 camshaft.