Valve and Cylinder Head Disassembly and Reassembly
Precautions: General safety (00)
NOTE:
Place disassembled parts except valve stem seal and valve guide in order so that they can be installed in their original position.
Disassembly
1)Using special tools (A) and (B), compress valve spring and then remove valve cotters (1) also using special tool (C).
NOTE:
To facilitate servicing cylinder head, remove injectors and exhaust manifold from cylinder head.
2)Release special tools, and remove spring retainer and valve spring.
3)Remove valve from combustion chamber side.
4)Remove valve stem seal (1) and valve spring seat (2).
5)Using special tool, remove valve guide from combustion chamber side to valve spring side.
Reassembly
NOTICE:
The engine could be damaged if shavings remain inside the valve guide hole after reaming it.
Thoroughly remove shavings from the reamed hole.
1)Before installing valve guide into cylinder head, ream guide hole with special tool to remove burrs and make the hole truly round.
2)Using special tools, install new valve guide to cylinder head as follows.
NOTE:
•Do not reuse valve guide. Install new valve guide.
•Intake and exhaust valve guides are identical.
•Intake and exhaust valve guides are identical.
a)Uniformly heat cylinder head uniformly to a temperature of 80 to 100 °C (176 to 212 °F) so that it will not be distorted, and drive new valve guide into its hole with special tools.
b)Install new valve guide until special tool contacts cylinder head.
After installation, check that valve guide protrudes from cylinder head by specified dimension “a”.
After installation, check that valve guide protrudes from cylinder head by specified dimension “a”.
Valve guide protrusion (In and Ex)
“a”: 11.1 – 11.5 mm (0.4370 – 0.4527 in.)
4)Install valve spring seat to cylinder head.
5)After applying engine oil to valve stem seal (1) and spindle of special tool (B), fit valve stem seal to spindle, and then install valve stem seal to valve guide by pushing special tool by hand.
After installation, check that valve stem seal is properly fixed to valve guide.
After installation, check that valve stem seal is properly fixed to valve guide.
NOTICE:
If the valve stem seal is installed by striking the special tool with a hammer or other similar tool, the valve stem seal may be damaged, causing oil to get down past the seal.
Push the special tool only by hand to force the valve stem seal into position.
6)Apply engine oil to valve guide bore and valve stem.
7)Install valve to valve guide.
8)Install valve spring and spring retainer.
Each valve spring has top end (large-pitch end (1)) and bottom end (small-pitch end (2)). Position spring in place with its bottom end (small-pitch end) facing the bottom (valve spring seat side).
Each valve spring has top end (large-pitch end (1)) and bottom end (small-pitch end (2)). Position spring in place with its bottom end (small-pitch end) facing the bottom (valve spring seat side).
| [a]: | Valve spring retainer side | 3. | Paint mark |
| [b]: | Valve spring seat side |
9)Use special tools to compress valve spring and fit two valve cotters (1) into groove in valve stem.
NOTE:
When compressing the valve spring, be careful not to damage inside surface of tappet installing hole.