Cylinder head components

Tools required:

Soft face hammer, screw driver, socket set, ring spanners, power bar, T bar set, vernier callipers, micrometre, ball gauge, feeler gauge, DDI gauge, straight edge and PPE (Safety boots, safety glasses and overalls)

Following the manufactures workbook we dismantled the Cylinder head taking measurements of internal components.

1.      Using a straight edge and feeler gauge we measured the head surface for warpage in six directions. Our head was less than 0.051mm warp which was in the 0.15mm manufacture specification. Also we checked the head for any form of damage such as cracks, broken edges, threads, corrosion, core plugs and camshaft bearings. All of ours was fine.

2.      Next we used a micrometer measuring the steam diameter at three points for cylinder three and four. Our average reading 5.97 - 5.98mm

3.      Measurements of the valve guide margins were next. We got 0.48mm reading without inlet valves and a 1.02mm reading with our Exhaust valves. The manufactures specifications was 0.5mm so the exhaust valves failed.

4.      After that multiple visual inspections were carried out of the general condition and serviceability of the valves. Checks were also made and reporting on our valve condition. Our valves were in good condition and none needed replacing

5.      After that we used a ball gauge to measure the valve guide clearance. The manufactures specifications were 0.025 - 0.060mm and we were getting readings such as 0.03-0.058 so each was within spec and passed.

6.      We then checked that the valve spring was square. Putting it up against a surface plate and using. The maximum specification was 1.6mm; our results were around 1mm so all two inlet and exhaust springs passed.

7.      Then we the free length of the spring. The same springs were tested and each passed within the 45.8 - 47.2mm specification.

8.      The next step was to calculate the valve spring installed height. We did this using vernier callipers. All our springs were under the 43.5 - 45mm specification so that was a fail.

9.      Last was the spring tension using the pressure tester. We put 20kg of pressure on two inlet and exhaust springs and our readings were from 37mm - 38 which was a fail compared to that 40mm specification.