Cylinder Heads, Camshafts, and Valve Trains: Martin Restoule Algonquin College

11
Cylinder Heads, Camshafts, and Valve Trains

Martin Restoule Algonquin College
Chapter 11
Copyright 2007 by Nelson, a division of Thomson Canada Limited.
Prepared by
11-1
Objectives
Describe the purpose of an engines cylinder head, valves, and related valve parts. Describe the types of combustion chamber shapes found on modern engines.
continued
Chapter 11
11-2
Objectives
Explain the procedures involved in reconditioning cylinder heads, valve guides, valve seats, and valve faces. Explain the steps in cylinder head and valve reassembly.
Chapter 11
11-3
Combustion Chamber Types

Wedge chamber
The spark plug is located at the wide part of the wedge.
Hemispherical chamber
The combustion chamber is shaped like a half circle. The spark plug is located in the centre of the combustion chamber.
continued
Chapter 11
11-4
Wedge Combustion Chamber
Chapter 11
11-5
Hemispherical Combustion Chamber
continued
Chapter 11
11-6
Valve Components
Intake valves Exhaust valves Valve guides Valve springs, retainers, keepers, and seals Valve rotators
Chapter 11
11-7
Intake and Exhaust Valves
Chapter 11
11-8
Valve Nomenclature
Chapter 11
11-9
Valve Guides
Valve guides
Integral or inserted bores in the cylinder head that support the valves in the head. Prevent oil from entering the combustion chamber during the intake stroke. Keep exhaust vapours from leaking into the crankcase area during the exhaust stroke. Keep the valve face in alignment with the valve seat.
continued
Chapter 11
11-10
Valve Guides
Chapter 11
11-11
Valve Guide Problems

Inadequate lubrication
Is caused by oil starvation in the upper valve train.
Valve geometry problems

Lead to increased guide clearance, poor valve seating, and premature wear.
Wrong stem to guide clearance

Can cause increased oil consumption.
Chapter 11
11-12
Valve springs
Valve springs hold the valve tight to the seat when closed and tight to the valve train when the camshaft is pushing the valve open. Valve springs come in a variety of designs to reduce vibration caused by harmonics during operation.
Chapter 11
11-13
Valve Spring Tests

Freestanding height test Spring squareness test Open/close spring pressure test
Chapter 11
11-14
Retainers and Keepers

Retainers and keepers are designed to positively hold the valve spring in place with the valve while allowing the spring to be removed for valve and spring service. The valve spring tension against the retainer holds the keepers tightly in the valves keeper grooves.
Chapter 11
11-15
Valve Seals
Valve seals control the amount of oil that is present at the top of the valve guide. Valve seals can be a passive or positive design.
Chapter 11
11-16
Valve Rotators
Valve rotators are used to rotate the valve to prevent the formation of carbon deposits on the valve face and from allowing the valve face from burning. A rotating valve will prevent the valve face from remaining in a constant hot location in the combustion chamber.
Chapter 11
11-17
Valve Rotators
Chapter 11
11-18
Timing Component Inspection

Inspect the timing belt or chain sprockets for wear or damage. Inspect the rocker shaft assembly for wear. Check the straightness of the pushrods. Check overhead cam follower components for damage and wear. Inspect retainers for cracks.
Chapter 11
11-19
Timing Component Service

Replace valve rotators when valves are refaced. Check valve spring assemblies for cracks, breaks, or damage. Carefully inspect cylinder heads after cleaning. Always replace cam bearings when rebuilding. Check valves for evidence of burning.
Chapter 11
11-20
Cylinder Head Reconditioning

Deck Resurfacing
To make the sealing surface flat so the gasket seals properly. To raise the compression ratio. To square the deck to the main bores. Depending on the tools available and the cylinder head material the deck can be resurfaced by grinding, milling, belt surfacing, or broaching.
continued
Chapter 11
11-21

The cylinder head deck surface can easily be checked for warpage with a precision straight edge and feeler gauge along the head and diagonally. Check your measurements against the specifications. continued
Chapter 11
11-22

Valve Resurfacing
Whenever the valves have been removed from the cylinder head, the valve face and valve seats should be resurfaced. Leakage between these surfaces reduces the engines compression and power and can lead to valve burning.
continued
Chapter 11
11-23

Valve Reconditioning
To ensure proper seating of the valve, the seat area on the valve face and seat must be the correct width, at the correct location, and concentric with the guide. These are accomplished by renewing the surface of the valve face and seat. Valve grinding or refacing is done by machining a fresh, smooth surface on the valve faces and stem tips.
continued
Chapter 11
11-24

Valve Resurfacing
Valve faces suffer from burning, pitting, and wear caused by opening and closing millions of times during the life of an engine. Valve stem tips wear because of friction from the rocker arms or actuators. Valve tips are machined after the valve face is refinished. Valves can be refaced on either grinding or cutting machines.
continued
Chapter 11
11-25

Performing the valve grinding operation;
Chuck the valve as close as possible to the valve head. Set the grinding angle according to the desired angle. Interference angles are normally 0.5 to 1 less than the seat.
Chapter 11
11-26

Performing the valve grinding operation;
Take light cuts using the full grinding wheel width. Make sure coolant is striking the valve face. Remove only enough metal to clean up the valve face.
continued
Chapter 11
11-27

Valve Guide Service
If guide measurements show guide wear the guide bore must be restored through machining or guide replacement. Slightly worn guides can be restored through knurling the guides bore. This is a quick and inexpensive repair that virtually does not affect the guides centreline and allows for the use of the old valve.
continued
Chapter 11
11-28

Reaming
Reaming is used to repair worn guides by increasing the guide hole size to take an oversize valve stem or by restoring the guide to its original diameter after installing inserts or knurling. When reaming, limit the amount of metal removed per pass. Always reface the valve seat after the valve guide has been reamed.
continued
Chapter 11
11-29

Thin Wall Guide Liners
Thin-wall guide liners offer a number of important advantages and are also popular with many production engine rebuilders, as well as smaller shops. It provides the benefits of a bronze guide surface. It can be used in either integral or replaceable guides. It is faster, easier, and cheaper than installing new guides in heads with replaceable or integral guides, and it maintains guide centring with respect to the seats.
continued
Chapter 11
11-30

Thin Wall Guide Liners
These liners can be cut to almost any length and are designed for a press fit. A tight fit is essential for proper heat transfer to the head and to prevent the liner from working loose.
continued
Chapter 11
11-31

Replaceable Guides
Replacing the entire valve guide is another repair option possible on cylinder heads with replaceable guides. Pressing out the old guides and installing new ones can be difficult with some aluminum heads because cracking the head or galling the guide hole is always a risk. The manufacturers specifications give the correct valve guide installed height
continued
Chapter 11
11-32

Concentricity
Occasionally, a new guide will not be concentric with the valve seat. Install a new seat to correct the problem and check the concentricity of the valve seat with a concentricity gauge.
continued
Chapter 11
11-33

Valve Seat Reconditioning
For proper seating of the valve, the valve seat must be the correct width, in the correct location on the valve face, and concentric with the guide. The ideal seat width for automotive engines is 1.59 mm for intake valves and 2.38 mm for exhaust valves. When an existing seat is refinished to make it smooth and concentric, it also becomes wider. continued
Chapter 11
11-34

Valve seats can be reconditioned or repaired by one of two methods, depending on the seat typemachining a counterbore to install an insert seat, or grinding, cutting, or machining an integral seat.
continued
Chapter 11
11-35

A properly reconditioned seat has 3 angles: top - 30/15; seat - 45/30; and throat - 60. Typically, the 45 angle seat wedges tighter and is used more often. Using 3 angles maintains the correct seat width and sealing position and pressure on the valve face.
continued
Chapter 11
11-36

When grinding a valve seat, it is very important to select and use the correct size pilot and grind stone. The stone must be properly dressed and cutting oil used to aid in grinding. The grinding wheel is positioned and centred by inserting a properly sized pilot shaft into the valve guide. All valve guide service must be completed before installing the pilot. continued
Chapter 11
11-37

Cutting valve seats differs from grinding only in the equipment used. Hardened valve seat cutters replace grinding wheels for seat finishing. The basic seat cutting procedures are the same as those for grinding.
Chapter 11
11-38
Summary
Every cylinder of a four-stroke engine contains at least one intake and one exhaust valve. Aluminum cylinder block and heads are often used on late-model engines because of their light weight.
Chapter 11
11-39
Summary
Multi-valve engines feature either three, four, or five valves per cylinder, which means better combustion and reduced misfire and detonation. The means of resurfacing the deck of a cylinder head include grinding, milling, belt surfacing, and broaching.
Chapter 11
11-40
Summary
Two critical measurements that must be made before a cylinder head is reassembled and installed are installed stem height and installed spring height. Valve guide problems include inadequate lubrication and incorrect geometry.
Chapter 11
11-41

Cylinder Heads, Camshafts, and Valve Trains: Martin Restoule Algonquin College

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11

Cylinder Heads, Camshafts, and Valve Trains

Copyright 2007 by Nelson, a division of Thomson Canada Limited.

Combustion Chamber Types

Wedge Combustion Chamber

Copyright 2007 by Nelson, a division of Thomson Canada Limited.

Hemispherical Combustion Chamber

Copyright 2007 by Nelson, a division of Thomson Canada Limited.

Intake and Exhaust Valves

Copyright 2007 by Nelson, a division of Thomson Canada Limited.

Copyright 2007 by Nelson, a division of Thomson Canada Limited.

Copyright 2007 by Nelson, a division of Thomson Canada Limited.

Valve Guide Problems

Valve geometry problems

Wrong stem to guide clearance

Copyright 2007 by Nelson, a division of Thomson Canada Limited.

Valve Spring Tests

Copyright 2007 by Nelson, a division of Thomson Canada Limited.

Retainers and Keepers

Copyright 2007 by Nelson, a division of Thomson Canada Limited.

Timing Component Inspection

Copyright 2007 by Nelson, a division of Thomson Canada Limited.

Timing Component Service

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Cylinder Head Reconditioning

Copyright 2007 by Nelson, a division of Thomson Canada Limited.

Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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