Valve, Spring, and Valve Seal Installation
Valves, Springs and Valve Seals RemovalSpecial Tools Required
^ Valve Spring Compressor Attachment 07757-PJ1010A
^ Commercially available Valve Spring Compressor KD383 with No.32 jaws
^ Commercially available Valve Guide Seal Remover KD3350
Identify the valves and valve springs as they are removed so that each item can be reinstalled in its original position.
1. Using an appropriate-sized socket (A) and plastic mallet (B), lightly tap the valve retainer to loosen the valve keepers.
2. Install the valve spring compressor. Compress the spring and remove the valve keepers.
3. Install the valve Guide seal remover (A).
4. Remove the valve seal.
Valve Inspection
Measure the valve in these areas.
Valve Stem-to-Guide Clearance Inspection
1. Slide the valve out of its guide about 10 mm, then measure the guide-to-stem clearance with a dial indicator while-rocking the stem in the direction of normal thrust (wobble method).
^ If the measurement exceeds the service limit, recheck it using a new valve.
^ If the measurement is now within the service limit, reassemble using a new valve.
^ If the measurement with a new valve still exceeds the service limit, go to step 2.
2. Subtract the O.D. of the valve stem, measured with a micrometer, from the I.D. of the valve guide, measured with an inside micrometer or ball gauge. Take the measurements in three places along the valve stem and three places inside the valve guide. The difference between the largest guide measurement and the smallest stem measurement should not exceed the service limit.
Intake Valve Stem-to-Guide Clearance:
Standard (New): 0.020 - 0.045 mm (0.0008 - 0.0018 inch)
Service Limit: 0.08 mm (0.003 inch)
Exhaust Valve Stem-to-Guide Clearance:
Standard (New): 0.055 - 0.080 mm (0.0022 - 0.0031 inch)
Service Limit: 0.12 mm (0.005 inch)
Valve Guide Replacement
Special Tools Required
^ Valve Guide Driver, 5.5 mm 07742-0010100
^ Valve Guide Reamer, 5.5 mm 07HAH-PJ7010B
1. As illustrated, use a commercially available air-impact valve guide driver (A) modified to fit the diameter of the valve guides. In most cases, the same procedure can be done using the special tool and a conventional hammer.
2. Select the proper replacement guides and chill them in the freezer section of a refrigerator for about an hour.
3. Use a hot plate or oven to evenly heat the cylinder head to 300°F (150°C). Monitor the temperature with a cooking thermometer. Do not get the head hotter than 300°F (150°C); Excessive heat may loosen the valve seats.
4. Working from the camshaft side, use the driver and an air hammer to drive the guide about 2 mm (0.1 inch) towards the combustion chamber. This will knock off some of the carbon and make removal easier. Hold the air hammer directly in line with the valve guide to prevent damaging the driver. Wear safety goggles or a face shield.
5. Turn the head over and drive the guide out toward the camshaft side of head.
6. If a valve guide won't move, drill it out with a 8 mm (5/16 inch) bit, then try again. Drill guides only in extreme cases; you could damage the cylinder head if the guide breaks.
7. Remove the new guide(s) from the freezer, one at a time, as you need them.
8. Apply a thin coat of clean engine oil to the outside of the new valve guide. Install the guide from the camshaft side of the head; use the special tool to drive the guide in to the specified installed height (A) of the guide (B). If you have all 12 guides to do, you may have to reheat the head.
9. Coat both the reamer and the valve guide with cutting oil.
10. Rotate the reamer clockwise the full length of the valve guide bore.
11. Continue to rotate the reamer clockwise while removing it from the bore.
12. Thoroughly wash the guide in detergent and water to remove any cutting residue.
13. Check the clearance with a valve. Verify that the valve slides in the intake and exhaust valve guides without exerting pressure.
Valve Seat Reconditioning
If the valve guides are worn, replace them before cutting the valve seats.
1. Renew the valve seats in the cylinder head using a valve seat cutter.
^ 1 Carefully cut a 45° seat, removing only enough material to ensure a smooth and concentric seat.
^ 2 Bevel the upper edge of the seat with the 30° cutter and the lower edge of the seat with the 60° cutter. Check the width of the seat and adjust accordingly.
^ 3 Make one more very light pass with the 45° cutter to remove any possible burrs caused by the other cutters.
2. After resurfacing the seat, inspect it for even valve seating: Apply Prussian Blue compound (A) to the valve face. Insert the valve in its original location in the head, then lift it and snap it closed against the seat several times.
3. The actual valve seating surface (B), as shown by the blue compound, should be centered on the seat.
^ If it is too high (closer to the valve stem), you must make a second cut with the 60° cutter to move it down, then one more cut with the 45° cutter to restore seat width.
^ If it is too low (closer to the valve edge), you must make a second cut with the 30° cutter to move it up, then one more cut with the 45° cutter to restore seat width.
NOTE: The final cut should always be made with the 45° cutter.
4. Insert the intake and exhaust valves in the head and measure the valve stem installed height (A).
5. If the valve stem installed height is over the service limit, replace the valve and recheck. If it is still over the service limit, replace the cylinder head; the valve seat in the head is too deep.
Valves, Springs and Valve Seals Installation
Special Tools Required
^ Valve Spring Compressor Attachment 07757-PJ1010A or 07VAE-001010A
^ Commercially available Valve Spring Compressor KD383 with No.32 jaws, commercially available
^ Commercially available Valve Guide Seal Remover KD3372, commercially available
1. Coat the valve stems with engine oil. Install the valves in the valve guides.
2. Check that the valves move up and down smoothly.
3. Install the spring seats on the cylinder head.
4. Install the new valve seals (A) using the valve guide seal installer (B).
NOTE: Exhaust valve seals (c) have a black spring (D) and intake valve seals (E) have a white spring (F); they are not interchangeable.
5. Install the valve spring and valve retainer. Place the end of the valve spring with closely wound coils toward the cylinder head.
6. Install the valve spring compressor. Compress the spring and install the valve keepers.
7. Lightly tap the end of each valve stem two or three times with a plastic mallet (A) to ensure proper seating of the valve and valve keepers. Tap the valve stem only along its axis so you do not bend the stem.
Camshaft/Rocker Arms, Camshaft Seal, and Pulley Installation
1. Apply a light coat of oil around the camshaft oil seal.
2. Gently tap the new camshaft oil seal (A) into the cylinder head.
^ 1 Tap the camshaft oil seal in squarely.
^ 2 Tap the oil seal into the cylinder head about 0.5 - 1.5 mm (0.02 - 0.06 inch) from the surface of the cylinder head.
3. Insert the camshaft (B) into the cylinder head, then install the camshaft thrust cover (C). Always use a new O-ring (D).
4. Check that the oil seal lips are not distorted.
5. Loosen the valve adjusting screws.
6. Set the rocker arm assembly in place and loosely install the bolts. Make sure that the rocker arms are properly positioned on the valve stems.
7. Tighten each bolt 2 turns at a time in the sequence shown to ensure that the rockers do not bind on the valves.
8. Install the injector base (A). Always use a new casket (B).
9. Install the back cover (A), then install the camshaft pulley (B).