Valves and Cylinder Head Disassembly and Reassembly
Valves and Cylinder Head Disassembly and ReassemblyDisassembly
1. When servicing cylinder head, remove intake manifold, injectors, exhaust manifold and water outlet cap from cylinder head.
2. Using special tools, compress valve springs and then remove valve cotters (1) also by using special tool.
Special Tool
(A):09916-14510
(B):09916-16510
(C):09919-28610
(D):09916-84511
3. Release special tool, and remove spring retainers and valve springs.
4. Remove valve from combustion chamber side.
5. Remove valve stem seal (1) from valve guide, and then valve spring seat (2).
NOTE: Do not reuse seal once disassembled. Be sure to use new seal when assembling.
6. Using special tool (Valve guide remover), drive valve guide out from combustion chamber side to valve spring side.
Special Tool (A):09916-46020
NOTE: Do not reuse valve guide once disassembled. Be sure to use new valve guide (oversize) when assembling.
7. Place disassembled parts except valve stem seal and valve guide in order so that they can be installed in their original positions.
Reassembly
1. Before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so as to remove burrs and make it truly round.
Special Tool
(A):09916-34542
(B):09916-38210
2. Install valve guide to cylinder head.
Heat cylinder head uniformly at a temperature of 80 to 100°C (176 to 212°F) so that head will not be distorted, and drive new valve guide into hole with special tools. Drive in new valve guide until special tool (Valve guide installer) contacts cylinder head. After installing, make sure that valve guide protrudes by specified value from cylinder head.
Special Tool
(A):09916-57350
(B):09916-57340
NOTE:
^ Do not reuse valve guide once disassembled. Install new valve guide (Oversize).
^ Intake and exhaust valve guides are identical.
Valve guide oversize 0.03 mm (0.0012 in.)
Valve guide protrusion "a"
In: 14.5 mm (0.57 in.)
Ex: 13.5 mm (0.53 in.)
3. Ream valve guide bore with special tool (6.0 mm reamer). After reaming, clean bore.
Special Tool
(A):09916-34542
(B):09916-37810
4. Install valve spring seat to cylinder head.
5. Install new valve stem seal (1) to valve guide.
After applying engine oil to seal and spindle of special tool (Valve guide installer handle), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by hand. After installing, check to be sure that seal is properly fixed to valve guide.
Special Tool
(A):09917-98221
(B):09916-57350
NOTE:
^ Do not reuse seal once disassembled. Be sure to install new seal.
^ When installing, never tap or hit special tool with a hammer or else. Install seal to guide only by pushing special tool by hand. Tapping or hitting special tool may cause damage to seal.
6. Install valve to valve guide.
Before installing valve to valve guide, apply engine oil to stem seal, valve guide bore, and valve stem.
7. Install valve spring and spring retainer.
Each valve spring has top end (large-pitch end (1)) and bottom end (small-pitch end (2)). Be sure to position spring in place with its bottom end (small-pitch end) facing the bottom (valve spring seat side).
8. Using special tool (Valve lifter), compress valve spring and fit two valve cotters (1) into groove in valve stem.
Special Tool
(A):09916-14510
(B):09916-16510
(C):09919-28610
(D):09916-84511
9. Install intake manifold.
10. Install exhaust manifold.
11. Install injectors.