Cylinder Heads and Valves Cylinder Heads n n

Cylinder Heads and Valves

Cylinder Heads n n n Purpose – regulates the air/fuel in/out of the engine Construction n Cast Iron n Cast Aluminum Overhead valve heads incorporate: n Valves @ related components n Coolant passages n Valve operation mechanism(s)

Cylinder Heads n Overhead camshaft heads will also incorporate: Camshaft(s) n Rocker arms or followers n

Hemispherical Cylinder Heads n n Hemi – a Chrysler term for a symmetrical cylinder design. Typically valves would be positioned directly opposite in the head with (ideally) a sparkplug positioned between them. n n Modern designs my incorporate two spark-plugs. NOT exclusive to Chrysler!

Hemi Head

Cylinder Heads n Cross flow head design – the practice of placing the intake port and the exhaust port on opposite sides of the cylinder head.

Traditional Arrangement n Traditionally, combustion chambers would have one exhaust valve and one intake valve.

Multiple Valves n Four valves per cylinder – two exhaust and two intake valves. n Pentroof design – each pair of valves are inline

Intake - Exhaust Ports n n The passageways in the cylinder head that lead to/from the combustion area. Intake: n Larger ports = more airflow n Smaller ports = better velocity for low RPM operation n Longer ports = better atomization on carb and TBI n Shorter ports = denser A/F charge

Gasket Matching Using an intake gasket as a template to “port” the heads •

Coolant Passages n n Coolant travels through the cylinder head from the engine block. Cylinder head gaskets may be designed to restrict coolant flow rate. n Often a source for corrosion and leakage.

n Blown Head Gasket

Cylinder Head Removal n All aluminum cylinder heads should be removed with a reverse torque procedure.

Cylinder Head Resurfacing n n Heads should be checked in five places for warpage, distortion, bends or twists. Check manufacturers specifications, maximum tolerances usually around. 004”.

Valve Guides n The “bore” in the cylinder head that supports and controls lateral valve movement. n Often integral on cast iron heads n Always an insert on aluminum heads

Valve Guides n Steel insert on aluminum heads

Valve Stem To Guide Clearance n Always check manufacturers specs n n n Intake valve will typically be. 001 to. 003” Exhaust valve will typically be. 002 to. 004” The exhaust valve stem clearance will generally be greater due to the higher operating temperatures.

Valve Guide Wear n Guides are checked in 3 locations n n With a small-hole gauge then measured with a micrometer Or checked with a small bore gauge

Valve Stem Wear n Measured with a micrometer at three separate locations.

Valve Stem To Guide Clearance Correction n Oversized Valve Stems – the guide is reamed to accept a larger stem. n Must use a valve with an oversized stem. n Reduced flow rate

Valve Stem To Guide Clearance Correction n Valve guide Knurling – a tool is driven into the guide that displaces metal thus reducing the inside diameter of the guide. (p. 340 -341) n n The guide is then reamed to attain proper clearance Not recommended for clearances +. 006

Valve Stem To Guide Clearance Correction n n Valve guide replacement – (insert) the old guide is driven out and a replacement guide is driven in. The guide may require reaming to achieve proper stem to guide clearance.

Valve Stem To Guide Clearance Correction n Valve Guide Inserts – (integral) the old guide is drilled oversized and inserts are installed. Pressed fit n May be steel or bronze n

Valve & Seat Service

Intake & Exhaust Valves n Automotive valves are of a poppet valve design.

Valve Materials n n Stainless steel n May be aluminized to prevent corrosion Aluminum n Hardened valve tips and faces n Stellite (nickle, chromium and tungsten) valve tips and faces n Stellite is nonmagnetic

Valve Materials n n Sodium-filled – a hollow stem filled with a metallic sodium that turns to liquid when hot (heat dissipation). Exhaust valves are largely comprised of a chromium material (anti-oxidant) with nickel, manganese and nitrogen added. n May be heat-treated n May be of a two-piece design

Intake & Exhaust Valves n n Valves are held into place by a retainer and keeper. Aluminum heads will have a separate spring seat (iron heads will have integral seats)

Valve Seats n n Integral seats – cast iron heads – inductionhardened to prevent wear Valve seat inserts – typically aluminum heads – hardened seats are pressed into the heads

Valve Inspection n Valve tips should not be mushroomed Most valve damage is due to excessive heat or is debris “forged”. Replace any valve that appears Burnt n n n Cracked Stressed Necked

Valve Springs n n n A spring “winds-up” as it is compressed – this causes the valve to rotate. May have inside dampers to control vibration. Springs are camshaft specific. n Squareness (+ (-). 060) n Spring free height (+ (-). 060) n Compressed force (+ (-) 10%) n Valve open height n Valve closed height

Valve Spring Tester

Valve Seat Reconditioning n n The angle of the valve seat is reconditioned. Often 3 stage (triple-angle) to promote flow and overhang. n n May be done with “seat stones” May also be done with a SERDI type set-up where the 3 angles are cut with one cutting tip.

Valve Reconditioning n n n The stem is lightly chamfered to insure proper fit in the valve grinder. The face of the valve is reground using a valve grinder. (45 or 30 degrees typical). Interference angle – the practice of grinding the face 1 degree less than the seat angle. n The valve must retain its “margin” area. n the stem should be ground ½ the value that the face was ground with nonadjustable rockers.

Valve Lapping n n The use of valve compound a suction cup stick to establish a pattern May be done to “freshen” the seat and face areas

Valve Lapping n n n The use of valve compound a suction cup stick to establish a pattern May be done to “freshen” the seat and face areas Also used to check the contact pattern while cutting valve seats All compound must be removed prior to service

Valve Seals n Valve Seals are designed to allow sufficient lubrication of the valve stem/guide and also control oil consumption. n Umbrella seals – hold tightly onto the valve stem n Positive valve stem seals – hold tightly onto the guide n O-rings – controls oil between the spring and retainer

Checking Installed Height n n If a valve seat and face are cut the valve will sit lower in the head. The result is that the stem will sit higher on the top of the head. This will cause the springs to have improper tension. Installed height is measured and shims are added under the spring to compensate.

Camshafts

Camshaft n The camshaft rotates ½ times the crankshaft – or – once per four-cycle stroke. The camshaft may operate the: n n Valve train Mechanical fuel pump Oil pump Distributor

Camshaft n n n Major function - operate the valve train. The lobes on the cam open the valves against the pressure of the valve springs. Bearing journal can be internally or externally lubricated (oiled).

When installing externally oiled cam bearings it is essential that the holes in the bearings lineup with the oil passages in the block

Camshaft n Pushrod engines have the cam located in the block. • Cam is supported by the block and the cam bearings.

Camshaft • Cam may or may not be held in place by a thrust plate. • Most roller camshafts are held in by a thrust plate.

Overhead Camshafts n Overhead camshafts are either belt or chain driven and are located in the cylinder heads.

Overhead Camshafts n Will use one of the following: n Cam followers n Rocker arms n n May have a one piece lifter – rocker design A bucket design

Camshaft Operation

Bucket Design

Camshaft Followers

Rocker Arms

Design n A cam casting will include n n n Lobes Bearing journals Drive flange (gear)

Design n A cam casting may include n n Oil pump drive gear(s) Fuel pump eccentric (mechanical fuel pump)

Classification n Camshafts are of one of four types: n n Hydraulic flat-tappet Hydraulic roller Solid flat-tappet Solid roller This designation is actually determined by the lifter design.

Hydraulic flat-tappet n n n The lifter is “spring” and oil loaded to allow for compensation. Traditional O. E. style (1950’s – mid 90’s) Used with flat or convex-faced lifters Generally cast iron or hardened steel Requires a “break-in” period to establish a wear pattern

Flat tappet Lifters

Hydraulic flat-tappet n Most cams are coated at the factory with manganese phosphate. This gives the cam a dull black appearance. This coating is to absorb and hold oil during the “break-in period”.

Hydraulic flat-tappet n Most late model designs use a convex bottom (. 002”) to encourage lifter rotation. n n This rotation helps reduce lifter and (or) bore wear. The Cam lobe will also be slightly tapered (. 0007” -. 002”). n This provides for a wider contact pattern.

Hydraulic flat-tappet Camshaft “break-in” n The lobes of the cam and the bottom of the lifters must be coated with a molydisulfide lubricant often called “cam lube”. n This insures that the cam is properly lubricated during “break-in”.

Hydraulic flat-tappet Camshaft “break-in” n Typical procedure – n n Maintain 1, 500 RPM for 10 - 20 minutes Drain the engine oil a immediately afterwards Check the recommended procedure and lube for your particular cam!

Hydraulic Roller n n The lifter is “spring” and oil loaded to allow for compensation. The contact between the cam and lifters are separated by a steel roller. n n This roller reduces friction. Lifters cannot be allowed to rotate within the lifter bore.

Hydraulic Roller n n A roller camshaft is generally made of non-hardened steel. The lobes must be “finished” by the manufacturer prior to assembly n there is no “break-in period”.

Hydraulic Lifters (tappets) n Hollow cylinders fitted with a plunger, check valve, spring and push-rod seat.

Hydraulic Lifters (tappets)

Hydraulic Lifters n n The oil passed through the check valve exits through the hole in the push rod seat. The oil then passes through the pushrod to lubricate the rocker arms.

• Engine oil pressure forces oil into the lifter through the oil inlet holes. • A check valve and ball hold most of the oil inside the lifter “hydrolocking” the plunger inside the cylinder.

Hydraulic Lifter Preload n n Also called valve lash. The distance between the pushrod seat and snap-ring when the lifter is resting on its base circle. Typical values range from. 020 to. 045”. Check manufacturers specifications.

Hydraulic Lifter Preload n Adjusted by: n Adjustable rocker arms n Often referenced by “turns past zero lash” Non-adjustable rocker arms n n n Longer or shorter pushrods Shim or grind rocker stands

Hydraulic Lifter Preload n Necessary if: n n n Cylinder head has been decked Cam has been changed Altered head gaskets Camshaft is worn An engine rebuild

Hydraulic Lifter Valve-float NOT GOOD n n n The lifter fills with oil faster than it can purge it. This raises the lift of the camshaft. Usually caused by excessive RPM. May damage valves, pushrods, pistons etc.

Solid Flat-tappet and Roller n n n No internal hydraulic absorption. Allows for a more consistent valve lift, especially at high RPM. Noisy when cold, more frequent and precise valve-lash adjustments required.

Solid Flat-tappet and Roller Oil is diverted through the pushrods via a pushrod seat.

Solid Flat-tappet and Roller n n n No lifter preload – valve lash only. Lash values may be given hot or cold Typical values range from. 002 -. 005”.

Cam Specifications n n Lift Duration Valve overlap Lobe center (separation angle or lobe spread)

Lobe Lift The amount the cam lobe lifts the lifter n Expressed in decimal inches n As lift increases the forces on the entire valve train also increase.

Lobe Lift n n Asymmetrical design – the amount of lift between the intake and exhaust lobes is different. Symmetrical design - the amount of lift between the intake and exhaust lobes is the same.

Duration n The number of degrees of crankshaft rotation for which the valve is lifted off of the seat. n If the amount of degrees that the intake and exhaust valve are open differ – it is of an asymmetrical design.

Duration Usually expressed as one of two values n n Duration (at zero lash) Duration at. 050” lift – preferred method n Compensates for tappet styles and clearances

Duration n n More duration = rougher idle and better high RPM performance Less duration = smoother idle and better low RPM performance

Valve Overlap n The number of degrees of crankshaft rotation that both valves are off of their seat (between the exhaust and intake strokes). n n Lower overlap = a smoother idle and better low RPM operation Higher overlap = better high RPM operation

Valve Overlap n Having the exhaust valve still open when the intake starts to open uses the exhaust "pull" out the exhaust port to help start the intake charge entering the chamber -- before the piston has started down and has generated it's own vacuum.

Lobe Separation Angle n The difference, in degrees, between the center of the intake lobe and the center of the exhaust valve. n n n The smaller the angle the greater the valve overlap The larger the angle the less the overlap Link to LSA effects

Camshaft (Valve) Timing n n It is crucial that the crankshaft, camshaft and balancing shaft (if equipped) are timed correctly. This is often achieved by aligning “timing marks” on the gears Pushrod- Type Engine

Camshaft (Valve) Timing n n Modern DOHC motors may incorporate chains and belts on the same motor Some of these designs are quite elaborate V-type DOHC Design

Camshaft (Valve) Timing n Some designs do not provide “alignment marks” and require special tools for proper timing

Camshaft Degreeing n Advanced cam timing n n The camshaft is slightly ahead of the crankshaft More low speed torque less high RPM power Retarded timing – The camshaft is slightly behind the crankshaft n More high RPM power n Reduced low RPM torque

Adjustable Camshaft Gear