201ka - Cylinder Head Service Flashcards

1
Q

What should be done before removing rocker arms and camshaft?

A

Loosen rocker arm adjusting screws

201ka pg. 4

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2
Q

Why should injectors and glow plugs be removed from the cylinder head before removing the head from the block?

A

They protrude below the bottom of the head and are easily damaged.

201ka pg. 5

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3
Q

What order should cylinder head fasteners be removed?

A

Opposite of torque sequence used for engine assembly

201ka pg. 6

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4
Q

How should a cylinder head be stored when off the engine?

A

On a set of wood blocks

201ka pg. 7

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5
Q

Where is a common place for cracks on a cylinder head?

A

Between valve seats and injector holes

201ka pg. 7

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6
Q

What should cylinder head cap screws be visually inspected for? (4)

A
  • Damaged or missing threads
  • Reduced diameter (stretched past elastic limit)
  • Corrosion or pitting
  • Stretch/Length

201ka pg. 9

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7
Q

What stiffness of wire brush should be used on cylinder head cap screws?

A

Soft bristle brush/wire wheel

201ka pg. 8

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8
Q

How should valves be stored when removed from the cylinder head?

A

Stored in order and marked to assist in diagnosis, measurement, and reassembly.

201ka pg. 11

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9
Q

What must be done to the cylinder head in preparation for pressure testing?

A

Seal all of the cylinder head coolant passages and plug injector tubes using dummy injectors

201ka pg. 12

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10
Q

What maximum pressure range is used when pressure testing a cylinder head?

A

20-40 psi

201ka pg. 13

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11
Q

When pressure testing a cylinder head, what temperature water is used and for how long is it left in the water?

A

180 - 200 F (83 - 93 C)
15 - 20 minutes

201ka pg. 13

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12
Q

What four main methods can be used to clean a cylinder head?

A
  • Petroleum solvent
  • Hot tank (not aluminum)
  • Mechanical parts washer
  • High temperature oven

201ka pg. 13

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13
Q

What would white scale indicate in the water jacket?

A

High concentration of minerals in the water that is mixed with the coolant

201ka pg. 18

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14
Q

What would green/blue deposits indicate if found in the water jacket?

A

An over-concentration of coolant

201ka pg. 18

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15
Q

What would rust or corrosion indicate in the water jacket?

A

Insufficient corrosion inhibitors in the cooling system.

201ka pg. 18

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16
Q

What should be done before measuring valve guides to ensure an accurate measurement?

A

Remove carbon buildup by using a valve guide scraper or brush.

201ka pg. 18

17
Q

What are two results of worn valve guides?

A
  • Loss of power
  • Oil consumption

201ka pg. 19

18
Q

What are two common valve face angles and what are their benefits?

A
  • 30 degrees - better airflow
  • 45 degrees - better seating force

201ka pg. 24

19
Q

What should be done with valves that have excessive runout?

A

Replaced. Do not try and straighten them.

201ka pg. 24

20
Q

After grinding down a valve face, what is the minimum margin thickness?

A

Not less than 1/2 the margin thickness of a new valve.

201ka pg. 25

21
Q

What would happen to a valve if operated with insufficient margin thickness?

A

Will run excessively hot and burn prematurely.

201ka pg. 25

22
Q

If a cylinder head is machined, where should it be stamped to indicate that it has been machined?

A

On a non-sealing surface of the cylinder head.

201ka pg. 27

23
Q

What are two methods of reconditioning integral valve guides?

A
  • Knurling
  • Repair sleeve

201ka pg. 28

24
Q

How can removable valve guides be removed from the cylinder head?

A
  • Ball peen hammer
  • Air chisel
  • Removal tool

201ka pg. 28

25
Q

What would result from a valve guide being installed too high in the cylinder head?

A

Component damage from contact between valve spring retainer and seal or top of guide.

201ka pg. 30

26
Q

How can valve seat inserts be removed?

A
  • Special chisel
  • Weld a bead around seat area
  • Insert puller tool

201ka pg. 31

27
Q

What is a valve seat insert concentricity check?

A

Checks that the valve seat is concentric with the valve guide. They must share the same centre line. Done by using a concentricity gauge and rotating it 360 degrees.

201ka pg. 34

28
Q

What tools are used to refinish valve seats?

A
  • Grinding stone - with a drill
  • Cutters - by hand

201ka pg. 35

29
Q

How is a valve seat interference angle formed?

A

By grinding the valve seat angle 0.5 to 1 degree greater than the valve face.

201ka pg. 36

30
Q

To form a valve interference angle, should the valve seat or face be ground the 0.5 to 1 degree greater?

A

Valve seat angle should always be 0.5 to 1 degree larger than valve face angle.

201ka pg. 36

31
Q

Where should the valve seat contact the valve face?

A

In the middle of the valve face.

201ka pg. 37

32
Q

What does a 15 degree stone do when grinding valve seats?

A

Lowers and narrows the contact area

201ka pg. 37

33
Q

What does a 60 degree stone result in when grinding valve seats?

A

Raises and narrows contact area

201ka pg. 37

34
Q

What valve seat cutting stone would be used to lower the contact area of the valve face?

A

A 15 degree stone

201ka pg. 37

35
Q

What valve seat stone would be used to raise the contact area?

A

A 60 degree stone

201ka pg. 37

36
Q

How do you check valve seat contact and width?

A
  • Spread a thin layer of Prussian Blue on the valve face
  • Insert valve into guide and press firmly without rotating
  • Remove valve and check where the Prussian Blue has been transferred from the valve to seat

201ka pg. 38

37
Q

How do exhaust valve seats compare to intake valve seats for size?

A

Exhaust valve seats are usually wider

Too wide - lowers seating force, carbon buildup, poor cooling

Too narrow - poor cooling, rapid wear

201ka pg. 38

38
Q

Valve head height (Protrusion) is a measure of what?

A

Distance from bottom of valve head to machined gasket surface of cylinder head.

Excessive height causes increased compression ratio
Insufficient height causes reduction in compression ratio

201ka pg. 39