2-1
Cylinder head
page
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Assembly of cylinder head.........................................................EM.2-12
To prevent the cylinder gasket from leaking air or water, the tightening torque of bolts on cylinder head shall
be checked using a torque wrench before new vehicles travel for 500 or1000 kilometers, and will be 90N.m for
ten M12 bolts, or 20N.m for three M8 bolts. And a tightening may not proceed until the engine cools down. To
perform a correct maintenance and adjustment, a general description is provided as below for dismantle /
inspection /maintenance of cylinder head.
valve locker
clamp
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valve spring
valve chamber cover valve spring upper seat (air
seat air exhaust inlet)
valve spring
rocker shaft and spring
valve oil seal
rocker shaft valve spring
lower seat
valve
spark plug
push rod
engine
spark plug sleeve
valve guide
cylinder head
water outlet pipe
hydraulic tappet
engine front
engine hook fender
Dismantle of cylinder head EM.2-3
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3. Piston for cylinder No. 1 will be placed to thetopdead
center of compression stroke.
Rotate the crankshaft pulley to have its groove facing exactly to mark
0 made on the timing chaincover.
6. Dismantle of rocker-shaft
Subject to the numbering sequence indicated in the figure, bolts and nuts
on rocker-shaft may be removed progressively in three steps.
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7. Dismantle of cylinder head
(a)Based on the bolt numbering sequence indicated inthe figure, a 12-edge
socket spanner shall be used tounscrew bolts on cylinder head
progressively in threesteps. Any dismantle in nonconformance with
theindicated sequence might cause a deformation or bendon cylinder
head.
(b)The cylinder head may be lift up from the connection surface of
device unit, and put onto a wood block onsaddle piece which has been
provided in advance.
Note Do not damage cylinder head, and the sur face of
device unit on one side having cylinder-cover spacer.
R emark If the cylinder head is hard to be lifted up, a screwdriver may
be used to prize the middle of convexity on cylinder head.
(c) Sealing ring will be removed from the cylinder head.
4. Dismantle of valve
(a)Valve spring seat will be compressed using SST until two valve locker
clamps have been removed.
SST 09202-43013
(b)SST and two valve locker clamps shall be removed.
(c) Take out valve spring seat, valve spring, and spring shim successively.
(d) Remove the oil-seal.
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(e) Disassembly the valve.
IN
EX
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6. Check the planeness of cylinder head
(a)Using precise ruler and feeler gage, measure the planeness on the
bottom surface of cylinder head, and check for flexuralde flection on the
contact surface between cylinder head and inlet /outlet manifold.
(b)The planeness on the bottom surface of cylinder head shall be
0.05mm.
(c)The planeness on the contact surface between cylinder head and inlet
/outlet manifold shall be 0.10mm.
(d)The cylinder head shall be changed if the measured planeness is greater
than the foresaid value.
External diameter of
Standard clearance Max. clearance
standard valve rod
Engine
Air Air Air
model Air inlet Air inlet
exhaust inlet exhaust
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valve valve
valve valve valve
(b)The valve guide may be struck out using SST and hammer.
SST 09201-60011
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11. Check and abrade the valve
(a)An abrading method will be applied to clear away any indent
or carbon deposit from the valve.
(b)Check whether the cone angle on valve surface has been
abraded to a correct angle.
Cone angle on valve surface 44.5
Note: The abraded amount shall be decreased to a Min.
degreewhen possible yet sufficient to remove any damage
remainedon the surface.
edge thickness
The valve shall be changed whereby the whole length of valve is less than
Min. value.
Cleanup /inspection on each spare part EM.2-9
(e)Check whether the valve rod has been abraded too much on endsurface.
If it does occur, a grinding machine may be used to repair the end surface,
or the valve shall be changed.
Note Do not mak e an over-abr asion to avoid thewhole
length of valve is less than M in. value.
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(c)The valve surface and the valve seat shall be checked as per the following:
-If the valve surface shows blue on the 360 circumference, it indicates
that the valve is homocentric, if not, the valve needs to be changed.
-If the valve seat shows blue on the 360 circumference, it indicates that
width the valve guide and the valve seat are homocentric, if not, the valve seat
needs to be abraded and repaired.
-Check whether the contacting width between valve seat and the middle
of valve surface is within (1.2 1.6) mm; If not, a modification to the
valve seat shall be made as per methods stated below:
-If the valve seat is much higher than the valve surface, 30 and 45
carbide tools shall be used to modify the valve seat.
(d)The valve and the valve seat may be manually abraded using
carborundum.
(e)Following a manual abrasion, the valve and the valve seat shall be
cleaned.
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(b)A vernier caliper will be used to check the freelength of valvespring.
Free length 47 0.5 mm
T he valve springshallbechangedifitcannotsatisfyspecifiedrequirements.
(c)A spring tester will be used to check the tensile force for each spring
having specified installation length.
Installation length:40.6 mm
Standard installation tensile force 345 N
M in. installation tensile for ce 282 N
T he spring shall be changed if the installation tensile force is less than
Min. installation tensile force.
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(c) Check whether the direction on the rear end of air valve rocker-shaft
is correct. And the valve spring and the rocker-shaft may be assembled as
indicated in the figure. During assembly, special maintenance tools may
be used for an installation of clamps. If the contact surface between valve
and.rocker shaft as been much abraded oil stone provided for valve
refacer may be used for abrading, or they may be changed.
SST 09207-71010
upward
front
convexity
convexity position
-When hydraulic tappet is submerged in light oil, push the plunger piston
for several times to discharge air insidethe hydraulic tappet.
SST 09276-71010
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-Check whether the oil hole on push rod has been blocked,if so,
compressive air may be applied to blow off any blocked material.
Note:
1. The thickness of cylinder head conforming to Class E ur opean
standar d shall be 0.5mm smaller than that confor ming to C lass
E ur opean standar d; A nd there’ s a mar k E 3 made on the r ight
side of cylinder head confor ming to C lass E ur opean standar d,
and the other one does not have this mar k.
2. A ny mis-installation across the E uropean- cylinder head and
the E ur opean- cylinder head is unallowable. I f E ur opean-
cylinder head was installed onto E ur opean-I I device by mistake, it
might make the valve touch the piston I f E ur opean- cylinder
head was installed onto E ur opean- device by mistak e, the
per for mance of engine might be degr aded, and other failur es might
occur accor dingly.
Assembly of cylinder head EM.2-13
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head has no any leakage; In case of leakage, the valve and its seat hole
shall be abraded accordingly.
4. A br ading on valve and valve seat hole
(a)A fter air inlet (exhaust) valve is removed, appropriate amount of
abrasive sands must be applied evenly to the coned sealing surface of air
valve and to the valve seat hole, then be installed into valve guide for an
abrasion by special abrading tool for (7~10) minutes.
(b)A fter air inlet (exhaust) valve is removed, kerosene will be used to
wash residual abrasive sands on valve, in the valve seat hole, inside the
combustion chamber, or inside the air inlet /exhaust duct.
R emark:Valves after an abrasion are not interchangeablewhen washing the
removed valves, they shall be placed in order by sequence to avoid any
mis-installation and misdetermination at a later stage.
marked with green color 5. Pressed installation of air inlet /exhaust valve
upward (a)A ppropriate amount of clean machine oil shall be taken out from
machine oil pot and be applied to the rod of eight air inlet / exhaust
valves respectively, then, have the cylinder head fixed onto a clamping
fixture applicable to the pressed installation of valves.
(b)I nstall eight valve spring seat gaskets successively into place.A nd
the number of gaskets must be correct.
(c)A special press tool shall be used during the pressed installation of
eight valve oil-seals.
Note F or ce applied to the oil-seal could not be too big,if the pr essed oil seal deviates fr om the
installation position, it shall be taken out and discar ded accor dingly,and may not be r e-
used any longer .
(d)Put the valve spring and the valve spring seat into place successively.
R emark
-T he smaller pitch end (viz colored end )of valve spring must be put to the downside.
-Different from air inlet valve, the spring seat on air exhaust valve has a rotatable mechanism, which can not be mis-installed.
SST 09202-43013
(e)Using a special press tool applicable to valve, each locker clamp of valve may be pressed into the cone hole on the cap of air inlet
/exhaust valve.
EM.2-14 Assembly of cylinder head
(f)To have the locker clamp of valve well connected with the spring seat
and the valve rod, a copper hammer may be used to strike gently against
the tail end of each valve rod.
6. Installation of spark plug component
(a)R espective sealing gasket shall be installed onto the spark plug sheath,
and the level end of sealing ring must be connected with the flanged
surface of socket.
(b)Insert the spark plug into the sleeve of spark plug.
(c)Four sets of spark plug and sleeve component shall be manually installed
into (by 3 4 threads) the installation hole on the right side of cylinder
head, and be tightened with a spark plug wrench.
T ightening tor que (20 3)N m
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A nd make it facing the bolt hole exactly.
( b)T wo M 8 20 bolts with standard spring washer may be
used to fix the front water tight cover plate as well as spacer component
onto the front side of cylinder head.
T ightening tor que (12 2)N m
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3. Rocker-shaft assembly
upward (a)Two rocker-shafts inside each cylinder may be fixed together via one
special clamping plate.
(b)The rocker-shaft assembly shall be installed onto two studbolts on
front
convexity the cylinder head in such a way that one endofrocker-shaft having dummy
club (its surface facing upward) will be backward.
SST 09207-71010
convexity position (c)Two M8 nut with flat washer may be manually screwed onto
stud bolt; Screw the short threaded end ofthree bolts (fixing the rocker-
shaft ) into the fixed seat for rocker-shaft, followed by a tightening made
push rod progressively in two steps as from the middle to two sides as shown
in the figure .
push rod Tightening torque ( 18 3)N m
(d)A fter a layer of clean machine oil has been applied to the ball surface
on two ends of the push rod, the lower end will be installed into a ball
socket on the tappet cap, while the upper end will be pressed by a special
press rod into the ball socket of rocker-shaft while the crankshaft is
rotating.
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manifold.
T ightening tor que ( 7 2) N m
(f)Installation of the upper part of air-inlet manifold
-Following a dismantle of dust-cover from the lower-part of air-inlet manifold,
connection spacers shall be installed onto a plane where the lower part and
the upper part of air-inlet manifold are connected, and shall face to six
installation holes exactly.
-T he upper part of air-inlet manifold shall be installed onto gaskets where the
lower part and the upper part of air-inlet manifold are connected, and have six installation holes facing exactly to relevant spacers, and
to six holes on the low part.
-Six M8 30 hexagonal socket head bolts with flat washer and standard spring washer will be used for fixing purpose, and
shall be tightened as per the sequence “from the middle to two ends”: a pre-tightening may be made using a pneumatic wrench before
a re-tightening to specified torque using a fixed-torque wrench.
Tightening torque ( 16 3)N m
(g)Installation of dead plate and the manifold supporting frame
-Using two M8 16 bolts with flat washer and standard spring washer , dead plate may be installed onto front end surface at
the lower /upper part of inlet manifold to link the lower part with the upper part. T ightening torque (16 3)N m
-One M8 16 bolt with flat washer and standard spring washer will be used to have the upper part of manifold supporting
frame on the rear side of cylinder head fixed onto the upper part of inlet manifold. And two bolts on manifold supporting frame may
be tightened using a fixed-torque wrench.
T ightening tor que ( 16 3)N m
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8. Installation of ignition coil components
Using three M 6 35 bolts with flat washer and light type spring
washer , ignition coil may be fixed on relevant supporting frame: flat
washer shall be applied to one side close to the ignition coil, and light-
type spring washer shallbe applied to one side close to the supporting
frame provided for ignition coil, followed by a tightening of M6nuts.
T ightening tor que ( 7 2) N m
9. I nstallation of high-tension damping wir ing
Two ends of high-tension damping wiring shall be connected to ignition
coil and spark plug respectively as indicated by relevant marks made on
high-voltage line and ignition coil.