Necessary equipment
KM-571-B Meter
KM-340-0 Cutting tool set
KM-340-7 Guide barb
KM–340–13 Cutting tools
KM–340–26 Cutting tools
KM-348 Valve Spring Compressor
KM-653 Adapter
KM-805 Valve guide knob
Disassembly procedure
1. Remove the cylinder head with the intake and exhaust manifold attached. follow the paragraph «Cylinder head and gasket» in this section.
2. Remove the exhaust manifold heat shield.
3. Remove the exhaust manifold lock nuts in the sequence shown.
4. Remove the exhaust manifold.
5. Remove the exhaust manifold gasket.
6. Remove the exhaust manifold pin.
7. Remove the thermostat housing mounting screws.
8. Remove the thermostat housing assembly.
9. Remove the coolant bypass mounting screws and housing.
10. Remove the fuel rail assembly. See Section 1F2, Engine Controls - FAM II 2.4D.
11. Remove the intake manifold retaining screws and nuts in the following order.
12. Remove the intake manifold support bracket.
13. Remove the intake manifold.
14. Remove the intake manifold gasket.
15. Remove intake manifold pin.
16. Remove cylinder head cover. Cm. "cylinder head cover" in this section.
17. Remove the direct ignition coil (DIS) and support bolts of the EGR valve adapter (EGR).
18. Remove the direct ignition coil (DIS) and EGR valve adapter (EGR).
19. Remove the spark plugs.
20. Gradually remove the camshaft bearing head screws in the sequence shown for each camshaft head.
21. Remove the intake camshaft heads. Choose the correct installation position.
22. Remove the intake camshaft.
23. Remove the intake valve tappet adjusters.
24. Remove the heads of the final camshaft. Choose the correct installation position.
25. Remove the exhaust camshaft.
26. Remove the exhaust valve tappet adjusters.
27. Compress the valve springs using the KM-348 valve spring compressor and KM-653 adapter.
28. Remove the valve spring caps.
29. Remove the KM-348 valve spring compressor and KM-653 adapter.
30. Remove the valve spring caps.
31. Remove the valve springs. Select the starting position for mounting the valve springs.
32. Remove valves. Select a starting position for mounting the valve.
Checking the cylinder head
1. Clean sealing surfaces.
2. Check the cylinder head as follows.
- Check for cracks, damage, or chipping on the surface of the ignition chamber.
- Are there foreign particles in the lubrication channels. Thoroughly clean the channels from foreign particles.
- Check for coolant leaks or damage to the top layer of the sealing surface. • Is there any damage to the surface of any of the gaskets.
- Is there any damage to the threaded holes of any of the bolts.
- Are there burnt or eroded areas in the combustion chamber.
- Are there any cracks in the intake ducts and in the combustion chambers.
- Are there any external cracks in the water channels.
- Are there any restrictions in the inlet or outlet ducts.
- Are there any restrictions on the ducts of the cooling system.
- Check for rusty, damaged or leaking plugs.
3. If cracks or damage are found on the cylinder head, it must be replaced. It is not recommended to carry out welding work on the cylinder head or repair damage.
4. Measure the clearance between the ruler and the face of the cylinder head at four points along the ruler using a gap gauge.
5. Check the sealing surfaces for deformation and distortion. The plane of the sealing surfaces of the cylinder head must be no more than 0.025 mm (0.001 inch).
6. Measure the height of the cylinder head from the sealing surface to the sealing surface. The height of the cylinder head must be between 133.975 and 134.025 mm (5.274 to 5.276 inches). If the cylinder head height is less than 133.9 mm (5.271 inches), the cylinder head needs to be replaced.
Checking valves
1. Check for damage to the valve from the head to the stop as follows.
- Is there surface chipping in the valve seat area? (1)
- Is the valve edge correct? (2)
- Is there a kink in the valve stem (3)
- Is there surface chipping or excessive wear in the stem (4)
- Are the valve key grooves worn? (5)
- Is the valve stop worn? (6)
2. Replace valve if any of these symptoms appear.
3. Check valve springs. If the end of the valve spring is not parallel, replace the valve spring.
4. Check the valve swivel seat for wear or chips. Replace if necessary.
Cleaning procedure
1. Clean the cylinder head.
2. Clean the valve guides.
3. Clean all threaded holes.
4. Clean the valves from soot, oil and carbon deposits.
Cylinder head overhaul
Valve lapping
1. Lubricate the valve seat with fine paste.
2. Lift the valve evenly off the seat using a commercially available valve sharpening tool to distribute the paste.
3. Check the contact pattern on the valve head and cylinder head.
4. Clean valves, valve guides and cylinder head.
Valve sharpening
1. Make sure that there are no burns on the valve head cone.
2. The valve can be reground no more than two times. Do not sharpen the end of the valve stem.
3. Make sure the valve face angle is 45 degrees.
4. Check the height of the intake and exhaust valve block.
Valve guide reamer
1. Measure the valve guide diameter using the MKM-571-B gauge and a commercially available internal micrometer.
Important: Oversized valves may have already been fitted at the factory.
2. The oversize code is located on the valve guide and valve stem end. The following table gives the correct dimensions, flat pattern, and production code for each service.
Size | Scan | Production code | Service code |
ordinary | - | - | TO |
0,075 | KM-805 | 1 | K1 |
0,150 | - | 2 | K2 |
3. Bore the valve guide from the top side of the cylinder head to the next oversize.
4. After reboring, cross out the code and stamp the new code on the valve guide.
Valve seat cutting
1. Install the cylinder head on a wooden block.
2. Cut off the inlet and outlet valve seats using a KM-340-7 cutter as follows:
- Valve seat - 45°surface using cutting tool KM-340-13.
- Upper correction angle - 30°surface using cutting tool KM-340-13.
- Lower correction angle - 60°surface using cutting tool KM-340-26.
3. Clean the chips from the cylinder head.
4. Check dimension for valve seat width.
- Inlet: 1.2 to 1.4 mm (0.047 - 0.055 inches)
- Outlet: 1.4 to 1.8 mm (0.055 - 0.070 inch)
5. Check the height of the intake and exhaust valve block. If the size is exceeded, install new valves. Check block height again. If the block height is still higher despite replacing the valves, replace the cylinder head.
Assembly procedure
1. Lubricate the valve stems with engine oil.
2. Carefully return the valves to their original position.
3. Install the valve springs to their original position.
4. Install the valve spring caps.
5. Compress the valve springs using the KM-348 valve spring compressor and KM-653 adapter.
6. Install the valve wedges.
7. Remove the KM-348 valve spring compressor and KM-653 adapter.
8. Lubricate the tappet adjusters with engine oil.
9. Install the valve lifter adjustment tools.
10. Install the intake camshaft.
11. Install the intake camshaft bearing heads to their original position.
12. Install the exhaust camshaft.
13. Install the exhaust camshaft bearing heads to their original position.
14. Install the camshaft bearing cap bolts in sequence for each camshaft cap in sequence.
Tighten
Tighten the camshaft bearing cap bolts to 8 Nm (71 lb-in.).
15. Install spark plugs.
Tighten
Tighten the spark plugs to 25 Nm (18 lb-ft).
16. Install the direct ignition coil (DIS) and EGR valve adapter (EGR).
Tighten
Tighten the fixing bolts for the direct ignition coil and the EGR valve adapter to 25 Nm (18 lb-ft).
17. Install the intake manifold pins.
18. Install the intake manifold gasket.
19. Install the intake manifold.
20. Install the intake manifold retaining screws and nuts in the order shown below.
Tighten
Tighten the intake manifold set screws and nuts to 22 Nm (16 lb-ft).
21. Install the intake manifold support bracket.
Tighten
Tighten the intake manifold support bracket bolts to 25 Nm (18 lb-ft).
22. Install the fuel rail assembly. See Section 1F2, Engine Controls - FAM II 2.4D.
23. Install the thermostat housing assembly.
Tighten
Tighten the mounting bolts of the thermostat housing assembly to 15 Nm (11 lb-ft).
24. Install the housing and the coolant bypass mounting screws.
Tighten
Tighten the coolant bypass housing screws to 15 Nm (11 lb-ft).
25. Install the exhaust manifold pins.
26. Install the exhaust manifold gasket.
27. Install the exhaust manifold.
28. Install the exhaust manifold lock nuts in the sequence shown.
Tighten
Tighten the exhaust manifold lock nuts to 22 Nm (16 lb-ft).
29. Install the exhaust manifold heat shield.
Tighten
Tighten the exhaust manifold heat shield bolts to 8 Nm (71 lb-in).
30. Install the cylinder head with the intake and exhaust manifolds attached. follow the paragraph «Cylinder head and gasket» in this section.