29. Valve Guide Reaming, and Valve and Seat Grinding

Valve Guide Reaming, and Valve and Seat Grinding

Special Tools

EN-49184 - Valve Guide Bushing Replacer

Valve Guides

1. Replace intake valve guide bush.
2. Heat the cylinder head to 80-100°C (176-212°F).
3. Place the cylinder head on wooden blocks.




4. Using EN-49184 - replacer (1) and a hammer, tap out the guide bush.




5. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

Cylinder Bore Diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in)

6. Select a new guide bush (STD or O/S 0.05).
7. If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in) to install an O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in), replace the cylinder head.
8. Heat the cylinder head to 80-100°C (176-212°F).
9. Place the cylinder head on wooden blocks.




10. Using EN-49184 - replacer (1) and a hammer, tap in a new guide bush to the specified protrusion height.

Protrusion Height: 9.9-10.3 mm (0.3898-0.4055 in)




11. Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard clearance between the guide bush and valve stem.

Standard Oil Clearance: 0.025-0.060 mm (0.0010-0.0024 in)

12. Replace the exhaust valve guide bush.
13. Heat the cylinder head to 80-100°C (176-212°F).
14. Place the cylinder head on wooden blocks.




15. Using EN-49184 - replacer (1) and a hammer, tap out the guide bush.




16. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

Diameter: 10.285-10.306 mm (0.4049-0.4057 in), select a new guide bush (STD or O/S 0.05)

17. If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in) to install an O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in), replace the cylinder head.
18. Heat the cylinder head to 80-100°C (176-212°F).
19. Place the cylinder head on wooden blocks.




20. Using EN-49184 - replacer (1) and a hammer, tap in a new guide bush to the specified protrusion height.

Protrusion Height: 11.15-11.55 mm (0.4390-0.4547 in.)




21. Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard clearance between the guide bush and valve stem.

Standard Oil Clearance: 0.030- 0.065 mm (0.0012-0.0026 in)

Note: It is not necessary to remove the ring pins unless they are being replaced.

22. Remove the ring pins.




23. Using a plastic-faced hammer, tap in new ring pins (1) to the specified protrusion height.

Protrusion Height: 6.5-7.5 mm (0.26-0.30 in)





Note: If any of the stud bolts is deformed or the threads are damaged, replace it.

24. Remove the stud bolts (1).





Caution: Refer to Fastener Caution (Fastener Caution).

25. Using an E8 TORX socket, install the stud bolts (1).

Tighten the bolts to 9.5 Nm (84 lb in).

Intake and Exhaust Valves





Note:
* Repair the seat while checking the seating position.
* Keep the lip free of foreign matter.

1. Using a 45 degree cutter, resurface the valve seat so that the valve seat width is more than the specification.




2. Using 30 degree and 75 degree cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat.
3. Handrub the valve and valve seat with an abrasive compound.
4. Check the valve seating position.