Disassembly And Assembly

CYLINDER HEAD


Disassembly and Assembly


DISASSEMBLY
1. Remove the following parts:
- Rocker cover and spark plug: Exploded View.
- Intake manifold: Exploded View.
- Exhaust manifold: Exploded View.
- Water inlet and thermostat housing: Exploded View.
- Water pipe and heater pipe: Exploded View.
- Timing chain: Exploded View.
- Camshaft (EXH) and VVEL ladder assembly: Exploded View.
2. Remove cylinder head.





- Loosen mounting bolts in reverse order as shown in the figure.

A : Bank 2
B : Bank 1
Arrow : Engine front

- Use TORX socket and power tool.
3. Remove cylinder head gaskets.
4. Remove oil filter (for VVEL ladder assembly) from cylinder block, if necessary.
5. Remove valve lifter.
- Identify installation positions, and store them without mixing them up.





6. Remove valve collet.
- Compress valve spring with the valve spring compressor [SST:
KV10116200 (J-26336-A)] (A), the attachment [SST:
KV10115900 (J-26336-20)] (C) and the adapter [SST:
KV10109220 ( -- )] (B). Remove valve collet with a magnet hand.

CAUTION:
When working, take care not to damage valve lifter holes.
7. Remove valve spring retainer and valve spring (with valve spring seat).
8. Push valve stem to combustion chamber side, and remove valve.
- Identify installation positions, and store them without mixing them up.





9. Remove valve oil seal using the valve oil seal puller [SST:
KV10107902 (J38959)] (A).
10. Remove valve seat (EXH), if valve seat (EXH) must be replaced.
- Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this. Cylinder Head.

CAUTION:
Prevent to scratch cylinder head by excessive boring.
11. Remove valve guide (EXH), if valve guide (EXH) must be replaced.





a. To remove valve guide (EXH), heat cylinder head to 110 to 130�C (230 to 266�F) by soaking in heated oil (A).





b. Drive out valve guide (EXH) with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 lmp ton) pressure] or a hammer and the valve guide drift (commercial service tool).

WARNING:
Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.

ASSEMBLY
1. Install valve guide (EXH), if removed.
Replace with oversized [0.2 mm (0.008 in)] valve guide (EXH).





a. Using the valve guide reamer (commercial service tool) (A), ream cylinder head valve guide (EXH) hole.

Oversize (service) [0.2 mm (0.008 in)]: Refer to "Cylinder Head". Cylinder Head

Heat cylinder head to 110 to 130�C (230 to 266�F) by soaking in b.





heated oil (A).





c. Using the valve guide drift (commercial service tool), press valve guide (EXH) from camshaft side to the dimensions as shown in the figure.

Projection (A) : Refer to "Cylinder Head". Cylinder Head

WARNING:
Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.





d. Using the valve guide reamer (commercial service tool) (A), apply reamer finish to valve guide (EXH).

Standard : Refer to "Cylinder Head". Cylinder Head

2. Install valve seat (EXH), if removed.
Replace with oversize [0.5 mm (0.020 in)] valve seat (EXH).





a. Ream cylinder head recess diameter (a) for service valve seat
(EXH).

Oversize (service) [0.5 mm (0.020 in)]: Refer to "Cylinder Head". Cylinder Head

- Be sure to ream in circles concentric to valve guide center.
This enables valve to fit correctly.





b. Heat cylinder head to 110 to 130�C (230 to 266�F) by soaking in heated oil (A).
c. Provide valve seats (EXH) cooled well with dry ice. Force fit valve seat (EXH) into cylinder head.

WARNING:
Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.

CAUTION:
Avoid directly touching cold valve seats.





d. Using the valve seat cutter set (commercial service tool) or valve seat grinder, finish seat to the specified dimensions. Cylinder Head.

CAUTION:
When using the valve seat cutter, firmly grip cutter handle with both hands. Then, press on the contacting surface all around the circumference to cut in a single drive. Improper pressure on cutter or cutting many different times may result in staged valve seat.
e. Using compound, grind to adjust valve fitting.
f. Check again for normal contact. Inspection.
3. Install new valve oil seals as per the following:
a. Apply new engine oil on new valve oil seal joint and seal lip.





b. Using the valve oil seal drift [SST: KV10115600 (J-38958)] (A), press fit valve seal to height (b) shown in figure.

Height (b)
Intake : 14.3 - 14.9 mm (0.563 - 0.587 in)
Exhaust : 13.6 - 14.2 mm (0.535 - 0.559 in)

4. Install valve.

NOTE:
Larger diameter valves are for intake side.





5. Install oil filter (for VVEL ladder assembly) (1) in the direction shown in the figure, if removed.
- Check that the oil filter does not protrude from the upper surface of cylinder block (2) after installation.
6. Install new cylinder head gaskets.
7. Install cylinder head as per the following:

CAUTION:
- If cylinder head bolts are re-used, check their outer diameters before installation. EM252, "Inspection".
- Before installing cylinder head, inspect cylinder head distortion. Inspection.





- Tighten cylinder head bolts in numerical order as shown in figure.

A : Bank 2
B : Bank 1
Arrow : Engine front

- Use TORX socket.
a. Apply new engine oil to threads and seat surfaces of cylinder head bolts.
b. Tighten all cylinder head bolts.

Tightening torque : 40 N-m (4.1 kg-m, 30 ft-lb)

c. Tighten all cylinder head bolts (clockwise).

Angle tightening: 75 degrees

d. Completely loosen all cylinder head bolts.

Tightening torque: 0 N-m (0 kg-m, 0 ft-lb)

CAUTION:
In step "d", loosen bolts in the reverse order of that indicated in the figure.
e. Tighten all cylinder head bolts.

Tightening torque : 40.0 N-m (4.1 kg-m, 30 ft-lb)

f. Tighten all cylinder head bolts (clockwise).

Angle tightening: 65 degrees

CAUTION:





Check the tightening angle using the angle wrench [SST:
KV10112100 (BT8653-A)] (A). Never make judgment by visual inspection.
- Check tightening angle indicated on the angle wrench indicator plate.
g. Tighten all cylinder head bolts again (clockwise).

Angle tightening: 65 degrees

8. Install valve spring (with valve spring seat).





- Install narrow pitch (B) end [paint mark (C)] to cylinder head side (valve spring seat side).

A : Wide pitch
Arrow: Cylinder head side

Paint mark color
Intake : Yellow
Exhaust : Pink

9. Install valve spring retainer.





10. Install valve collet.
- Compress valve spring with the valve spring compressor [SST:
KV10116200 (J26336-A)] (A), the attachment [SST:
KV10115900 (J26336-20)] (C) and the adapter [SST:
KV10109220 ( -- )] (B). Install valve collet with a magnet hand.

CAUTION:
When working, take care not to damage valve lifter holes.
- Tap valve stem edge lightly with plastic hammer after installation to check its installed condition.
11. Install valve lifter.
- Install it in the original position.
12. Install in the reverse order of removal.