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 Cylinder Head Crack Inspection
• Cracks are sometimes found:
 In combustion chambers
 Between adjacent combustion chambers
 On the valve spring side of the head
• Cracks in metal castings are the result of:
 Fatigue may result from repeated stress cycles.
 Chilling of a hot engine by a sudden rush of cold
water or air over the surface.
 Excessive overheating is possible due to improper
operation of an engine system.
• Ways to detect cracks
1. Magnetic crack inspection
2. Dye penetrant
3. Pressure testing

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 1. MAGNETIC CRACK INSPECTION
 Checking for cracks using a magnetic field is commonly called
Magnafluxing.
 Magnetic lines of force are easily conducted
through the iron part and concentrate on the
edges of a crack.
 A fine iron powder is then applied to the part
being tested, and the powder will be attracted to
the strong magnetic concentration around the
crack.

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A magnetic crack detector
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 2. DYE PENETRANT
a
Checking for cracks with a dye penetrant.
(a) Spray on penetrant.
(b) After 5 minutes, Spray the cleaner onto a clean
cloth and wipe off all visible penetrant. b

(c) Spray on developer to highlight the crack, wait

until the developer is totally dry and
(d) finally inspect the area. Crack will appear as a
red line. c

D
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 3. PRESSURE TESTING
 Coolant passages are blocked
with rubber plugs or gaskets, and
compressed air applied to the
water jacket(s). The head or block
A custom-fitted pressure test plate
is lowered into water, where air installed on a cylinder head
bubbles indicate a leak.
 For more accurate results, the
water should be heated
because the hot water expands
the casting by about the same
amount as an operating engine
would.

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 2. Cylinder Head Crack Repair
• Cracks in the cylinder head will allow coolant to leak into
the engine, or allow combustion gases to leak into coolant.
• Cracks across the valve seat cause hot spots on the valve,
which will burn the valve face.
• A cracked head will either have to be replaced or the crack
will have to be repaired.
• Two methods of crack repair are:
 Crack welding
 Crack Plugging

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 3. Checking Cylinder Head Flatness
 Clean the head surface before
checking for flatness.
 Use a straightedge and feeler
gauge diagonally, vertically, and
horizontally on the head.
When checking for warp on
the ends of a head, be sure to
use a feeler gauge and straight
rock the straight edge to the edge
opposite side of the head.
The head should be checked
in five planes as shown in
Figures, for warpage,
distortion, bend, and
twist. Check in five planes) ( diagonally,
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vertically and horizontally
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 4. Measuring Valve Guides for Wear
• Valve guides support the valves in the head and prevent the
valves from moving in any direction other than up and down.
 Valves stem should be measured for wear before valve guides
are measured.
 The dimension of the valve stem diameter is
subtracted from the dimension of the valve
guide diameter.
 If the clearance between the stem and
the guide exceeds the specified clearance,
the valve guide will have to be
reconditioned.
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 The valve stem diameter should be measured
in three places (top, middle and bottom) by
micrometer. The difference between the
maximum inside diameter of the valve guide
and minimum diameter of the valve stem is the
valve guide to valve stem clearance.
• Valve stem-to-valve guide clearance can also be checked using a dial
indicator (gauge) to measure how much the valve moves when it is
lifted off the valve seat.
• Measuring valve guide-to-stem clearance
with a dial indicator while rocking the
stem in the direction of normal thrust.
• The reading on the indicator is the total
movement of the valve and is indicative of
the guide’s wear.
• The reading on the dial indicator should be
compared to specification.
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 5. Valve Spring Inspection
 The high stresses and temperatures imposed on valve
springs cause them to weaken and sometimes break.
 Test valve springs for :

A. Height

B. Squareness and

C. Tension
• A. Free length of the valve spring
• The free length of the valve spring is measured by vernier
caliper.

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B. Test springs for squareness
 Valve springs must close the valve
squarely to form a tight seal and to
prevent valve stem and guide wear.

 Checked for squareness by rotating on a

flat surface with a try square held
against the side.

 Discard springs that are out of

specification.

 Out-of-square springs can cause

excessive, uneven valve guide wear.
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 C. Measure the Valve Spring Tensions
• A valve spring scale is used to
measure the valve spring force.
• One popular type of valve spring tester
used to measure the compressed force of
valve springs.
• Valve springs are checked for:
 Free height (without being compressed)
should be within limit.
 Force with valve closed and height as
per specifications (with damper spring
removed)
 Force with valve open and height as per
specifications (with damper spring
removed).
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 check each lobe for scoring, scuffing, fractured surface,
pitting, and signs of abnormal wear; also check for plugged oil
passages.
1. Check cam lobe wear, measure the lobe height with a
micrometer. (Fig A).
2. Measure each camshaft journal diameter in several places
to determine if it is worn.
 If measurement is below the manufacturer’s specifications, it
should be replaced (Fig B).

A B
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3. Check camshaft for Run-out with a dial
indicator (Fig C).

4. Check Camshaft Thrust Clearance by

using feleer gauge (Fig D).

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 • Pushrods can be visually checked for.

• they can be checked for straightness by rolling them over a flat surface
such as a surface plate Fig.(b)).

– If a pushrod is not straight, it will appear to hop as it is rolled.

– However, the most accurate way to check for straightness is by

using a dial indicator.

 Inspect the pushrod end and rocker arm surfaces for pitting or other
unusual wear (see fig.(a)).

(b)

(a)

Roll pushrods on a flat surface

Inspect both ends of each pushrodDefence
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• Inspect the rocker arms for wear, especially at points that
contact the valve stem and pushrod.
• Make sure the oil feed bore in each rocker arm is clear and not
plugged with dirt.
• The fit between a rocker arm and its shaft is checked by
measuring the outside diameter of the shaft and comparing it
to the inside diameter of the rocker arm.
• Excessive clearance requires replacement of the rocker arm
or the rocker shaft, or both.
• Another wear point that should be checked is the pivot area of
the rocker arm.

Measure the inside diameter of the rocker arm

and check for an out-of-round condition.

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