Disassembly And Assembly

CYLINDER HEAD

Disassembly and Assembly


DISASSEMBLY

1.Remove the following parts:
- Intake manifold collector: Exploded View.
- Fuel tube and fuel injector assembly: Exploded View.
- Intake manifold: Exploded View.
- Rocker cover: Exploded View.
- Exhaust manifold: Exploded View.
- Water inlet and thermostat assembly: Exploded View.
- Water outlet, water pipe and heater pipe: Exploded View.
- Timing chain: Exploded View.
- Rear timing chain case: 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.





- Use the cylinder head bolt wrench (commercial service tool: J24239-01) and power tool.
3.Remove cylinder head gaskets.
4.Remove spark plug with spark plug wrench (commercial service tool).
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:
KV-10116200 (J-26336-A)] (A), the attachment [SST:
KV-10115900 (J-26336-20)] (C), and the adapter [SST:
KV-10109220 (-)] (B). Remove valve collet with a magnet hand.

CAUTION:
When working, take care not to damage valve lifter holes.
7.Remove valve spring retainer, valve spring and 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:
KV-10107902 (J-38959)] (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. [1][2]Cylinder Head Assembly.

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.If valve guide (EXH) is removed in step 11 (DISASSEMBLY), install it.
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)]:
: [1][2]Cylinder Head Assembly.





b.Heat cylinder head to 110 to 130�C (230 to 266�F) by soaking in 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)
: [1][2]Cylinder Head Assembly.

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: [1][2]Cylinder Head Assembly.
2.If valve seat (EXH) is removed in step 10 (DISASSEMBLY), install it.
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)]:
: [1][2]Cylinder Head Assembly.
- Be sure to ream in circles concentric to valve guide center.
This will enable 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. Refer to
[1][2]Cylinder Head Assembly.

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. Refer to "VALVE SEAT CONTACT".
3.Install new valve oil seals as follows.
a.Apply new engine oil on new valve oil seal joint and seal lip.





b.Using the valve oil seal drift [SST: KV-10115600 (J-38958)] (A), press fit valve seal to height (b) shown in figure.
NOTE:
Dimension: Height measured before valve spring seat installation
Height (b): 14.3 - 14.9 mm (0.563 - 0.587 in)
4.Install valve spring seat.
5.Install valve.
NOTE:
Larger diameter valves are for intake side.
6.Install new cylinder head gaskets.
7.Turn crankshaft until No. 1 piston is set at TDC.





- Crankshaft key should line up with the cylinder center line (bank 1) as shown in the figure.










8.Install cylinder head, and tighten cylinder head bolts in numerical order as shown in figure as follows:





- Use the cylinder head bolt wrench (commercial service tool: J24239-01) and power tool.

CAUTION:
- If cylinder head bolts are reused, check their outer diameters before installation. Inspection.
- Before installing cylinder head, inspect cylinder head distortion. Inspection.
a.Apply new engine oil to threads and seat surfaces of cylinder head bolts.
b.Tighten all cylinder head bolts.





c.Completely loosen all cylinder head bolts.





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





e.Turn all cylinder head bolts 95 degrees clockwise (angle tightening).

CAUTION:





Check the tightening angle using the angle wrench [SST: KV-10112100 (BT-8653-A)] (A). Never make judgment by visual inspection.
- Check tightening angle indicated on the angle wrench indicator plate.
f.Turn all cylinder head bolts 95 degrees clockwise again (angle tightening).





9.After installing cylinder head, measure distance between front end faces of cylinder block and cylinder head (bank 1 and bank
2).
Standard: 14.1 - 14.9 mm (0.555 - 0.587 in)
- If measured value is out of the standard, reinstall cylinder head.
10.Install valve spring (uneven pitch type).





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





Paint mark color
Intake: Purple
Exhaust: Yellowish green

11.Install valve spring retainer.
12.Install valve collet.





- Compress valve spring with the valve spring compressor [SST:
KV-10116200 (J-26336-A)] (A), the attachment [SST:
KV-10115900 (J-26336-20)] (C), and the adapter [SST:
KV-10109220 (-)] (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.
13.Install valve lifter.
- Install it in the original position.
14.Install spark plug with spark plug wrench (commercial service tool).
15.Install in the reverse order of removal after this step.