Toyota Corolla 2004 Repair Manual - CYLINDER HEAD ASSY
14–134
OVERHAUL
–ENGINE MECHANICAL CYLINDER HEAD ASSY
140Q7–04
1. REMOVE W/HEAD TAPER SCREW PLUG NO.2
(a) Using a socket hexagon wench 10, remove the taper
screw plug and gasket.
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2. REMOVE VALVE LIFTER
(a) Remove the valve lifters from the cylinder head.
SST
A62891
Wooden
Block
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3. REMOVE VALVE
(a) Place the cylinder head on wooden blocks.
(b) Using SST, compress the inner compression spring and
remove the 2 valve spring retainer locks.
SST 09202–70020 (09202–00010, 09202–01010,
09202–01020)
(c) Remove the valve spring retainers, inner compression
springs and valves from the cylinder head.
4. VALVE STEM OIL O SEAL OR RING
(a) Using a needle–nose pliers, remove the valve stem oil
seals.
2004 COROLLA (RM1037U)
1144Author: Date:
–ENGINE MECHANICAL CYLINDER HEAD ASSY
5. REMOVE VALVE SPRING SEAT
(a) Using a compressed air and a magnetic finger, remove
the valve spring seats.
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6. REMOVE STUD BOLT
(a) Using torx socket wrench E5 and E7, remove the 11 stud bolts.
Front side:
14–135
Upper side:
Cylinder block side:
Intake side:Exhaust side:
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7. INSPECT CYLINDER HEAD FOR FLATNESS
(a) Using a precision straight edge and a feeler gauge, mea-
sure the surface contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
Cylinder block side 0.05 mm (0.0020 in.)
Intake manifold side 0.10 mm (0.0039 in.)
Exhaust manifold side 0.10 mm (0.0039 in.)
If the warpage is greater than maximum, replace the cylinder
head.
Intake manifold side:
Exhaust manifold side:
2004 COROLLA (RM1037U)
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1145Author: Date:
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Width
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–ENGINE MECHANICAL CYLINDER HEAD ASSY
8. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrate, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface for
cracks.
9. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve against the seat.
NOTICE:
Do not rotate valve.
(c) Check the valve face and seat according to the following
procedure.
(1) If blue appears 360 around the face, the valve is
concentric. If not, replace the valve.
(2) If blue appears 360 around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the
valve face with the width between 1.0 – 1.4 mm
(0.039 – 0.055 in.).
1.0 – 1.4 mm
(0.039 – 0.055 in.)
45
30
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10. REPAIR VALVE SEATS
NOTICE:
Take off a cutter gradually to make smooth valve seats.
(a) If the seating is too high on the valve face, use 30 and
45 cutters to correct the seat.
2004 COROLLA (RM1037U)
1146Author: Date:
Intake:
1.0 – 1.4 mm
(0.039 – 0.055 in.)
60
45
14–137
–ENGINE MECHANICAL CYLINDER HEAD ASSY
(b) Intake:
(1) If the seating is too low on the valve face, use 60
and 45 cutters to correct the seat.
(c) Exhaust:
(1) If the seating is too low on the valve face, use 75
and 45 cutters to correct the seat.
(d) Hand–lap the valve and valve seat with an abrasive com-
pound.
(e) Check the valve seating position.
Exhaust:
1.0 – 1.4 mm
(0.039 – 0.055 in.)
Plastigage
75
45
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11. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the 2 camshafts.
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.040 – 0.095 mm (0.0016 – 0.0037 in.)
Maximum thrust clearance: 0.110 mm (0.0043 in.)
If the thrust clearance is greater than maximum, replace the cylinder head. If damages are found on the camshaft thrust surfaces, the camshaft also has to be replaced.
12. INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of plastigage across each of the camshaft jour-
nal.
(d) Install the bearing caps. (See page 14–45 )
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps. (See page 14–45)
2004 COROLLA (RM1037U)
(f) Measure the plastigage at its widest point.
Standard oil clearance:
0.035 – 0.072 mm (0.0014 – 0.0028 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
NOTICE:
Completely remove the plastigage after the measuring.
If the oil clearance is greater than maximum, replace the cylinder head.
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