Assembly
Legend
1 Oil filler cap
2 Rocker cover
3 Rocker arm guide
4 Rocker arm
5 Shim
6 Hydraulic lash adjuster
7 Chain tensioner
8 Camshaft sprocket
9 Camshaft
10 Camshaft bracket
11 Oil tube
12 Water outlet
13 Cylinder head
14 Valve
15 Valve spring seat
16 Valve spring
17 Valve spring retainer
18 Valve collet
19 Spark plug
20 Cylinder head bolt
CAUTION:
^ When installing sliding parts such as rocker arms, camshaft and oil seal, be sure to apply new engine oil on their sliding surfaces.
^ When tightening cylinder head bolts, camshaft sprocket bolts and camshaft bracket bolts, apply new engine oil to thread portions and seat surfaces of bolts.
^ If a hydraulic lash adjuster is kept on its side, there is a risk of air entering it. After removal, always set hydraulic lash adjuster straight up, or when laying it on its side, have it soak in new engine oil.
^ Do not disassemble hydraulic lash adjusters.
^ Attach tags to lash adjusters so as not to mix them up.
ASSEMBLY
1. Install water connector.
(1) Before installing water connector, remove all traces of liquid gasket from mating surface using a scraper.
^ Also remove traces of liquid gasket from mating surface of cylinder head.
(2) Apply a continuous bead of liquid gasket to mating surface of water connector.
^ Use Genuine Liquid Gasket or equivalent.
Fig. 34 Thermostat Housing & Water Pipe Bolt Tightening Sequence:
2. Install thermostat housing with water pipe.
^ Tightening procedure:
(1) Tighten bolt (A) to 2 - 5 Nm (0.2 - 0.5 kg-m, 1.4 - 3.6 ft-lb).
(2) Tighten bolt (C) to 16 - 21 Nm (1.6 - 2.1 kg-m, 12 - 15 ft-lb).
(3) Tighten bolt (A) to 16 - 21 Nm (1.6 - 2.1 kg-m, 12 - 15 ft-lb).
(4) Tighten bolt (B) to 16 - 21 Nm (1.6 - 2.1 kg-m, 12 - 15 ft-lb).
^ Perform steps (2) through (4) after installing cylinder head on cylinder block.
3. Install water outlet.
(1) Before installing water outlet, remove all traces of liquid gasket from mating surface using a scraper.
^ Also remove traces of liquid gasket from mating surface of cylinder head.
(2) Apply a continuous bead of liquid gasket to mating surface of water outlet.
^ Use Genuine Liquid Gasket or equivalent.
4. Install intake manifold collector to intake manifold.
5. Install intake manifold.
6. Install fuel tube assembly.
Refer to "Injector Removal and Installation".
7. Install exhaust manifold.
8. Install exhaust manifold cover.
9. Install E.G.R. tube.
10. Install throttle chamber with accel-drum unit.
11. Adjust accel-drum unit.
Refer to "ACCEL-DRUM UNIT".
12 Check Valve Spring.
^ Always use new valve oil seal. Refer to OIL SEAL REPLACEMENT.
^ Before installing valve oil seal, install valve spring seat.
^ Install valve spring (uneven pitch type) with its narrow pitched side toward cylinder head side (paint mark).
^ After installing valve component parts, use plastic hammer to lightly tap valve item tip to assure a proper fit.
Fig. 35 Checking Hydraulic Lash Adjuster:
13. Check hydraulic lash adjusters.
(1) When rocker arm can be moved at least 1 mm (0.04 in) by pushing at hydraulic lash adjuster location, it indicates that there is air in the high pressure chamber.
Noise will be emitted from hydraulic lash adjuster if engine is started without bleeding air.
Fig. 36 Bleeding Hydraulic Lash Adjuster:
(2) Remove hydraulic lash adjuster and dip in a container filled with engine oil. While pushing plunger as shown in image, lightly push check ball using a thin rod. Air is completely bled when plunger no longer moves.
Air cannot be bled from this type of lash adjuster by running the engine.
14. Remove camshafts, rocker arms and shims. For future reference, identify each shim with the cylinder it was removed from. Since the shims are reusable, it may not be necessary to replace all of the existing shims.
15. Before attempting any measurement, make sure the valve, valve spring, collet, retainer and rocker arm guide are properly installed in the head.
^ Always replace rocker arm guide with a new one.
CAUTION: Install parts in their original positions.
16. Install the J38957-1 gauge plate into the tapped holes at the cam journals and secure it to the head using two of the hex bolts supplied with the kit. The two remaining bolts are spares).
17. Place the J38957-2 collar on the J38957-8 dial indicator. Make sure the dished side of the collar is facing "up" (toward the dial indicator). Secure the collar to the dial indicator by tightening the set screw in the collar
18. Place the indicator and collar over #1 cylinder intake valve, shim side. Slide the tip of the dial indicator through the access hole and place it on the end of the valve stem. While resting the dial indicator collar on the gauge plate, "zero" the dial indicator.
19. Move the dial indicator and collar to the adjacent hole in the gauge plate and place the tip of the indicator in the center of the rocker arm guide. Write down the dial indicator reading. This measured distance between the valve stem end and the contact surface of the rocker arm guide is the "T1" dimension.
20. Match the measured "T1" dimension (in inches) to the available shim chart (in millimeters) located in Specifications. The "T1" dimension is equivalent to the thickness and size designation of the valve shim). Select the closest size shim to the measured "T1" dimension. For example, if the measured "T1" dimension is 0.1154 in. use a 2.925 mm shim. Shims are available in 17 different thicknesses ranging from 2.800 mm (0.110 in.) to 3.200 mm (0.126 in.) and increase in increments of 0.025 mm (0.001 in.).
21. Repeat this procedure on the remaining cylinders.