Special Tools

J 8001 Dial Indicator Set

For equivalent regional tools, refer to Special Tools.

1. Recondition the valve seats by grinding. Use an oscillating type valve seat grinder. Follow the grinder manufacturer's instructions. If the valve seat is too wide after grinding, use a 20 degree stone or a 70 degree stone in order to narrow the valve seat. The 20 degree stone will lower the seat. The 70 degree stone will raise the seat. Replace or recondition the valves if the seats are reconditioned.
2. After grinding the valves, measure the valve margin. Replace the valve if less than the minimum recommended specification (0.79 mm (0.031 in).

Warning: Refer to Cleaning Solvent Warning in the Preface section.

Caution: Clean the valve guides before reaming. Packing of chips or carbon may result in the reamer jamming into the valve guide or broken reamer flutes.

3. Clean any foreign material from the valves. Use a wire brush to remove carbon. Do not scratch the valve stem. Soak the valves in cleaning solvent to remove varnish.
4. Use a suitable tool to clean the valve guides.
5. Follow the grinder manufacturer's instructions. Ensure that the new surface is perpendicular to the valve stem.



6. Inspect the valve key grooves for chipped or worn lands (5). Replace the valve if the valve key groove is damaged.
7. Inspect the valve stem tip for wear (6). Recondition the valve stem tip by grinding.
8. Inspect the valve stem for burrs and scratches (4). Use an oil stone to remove burrs and minor scratches.
9. Inspect the valve stem for straightness (3). Use V blocks to inspect the valve head for bending or distortion. Replace any bent or distorted valves.
10. Inspect the valve face for grooving (1, 2). If the groove is so deep that refacing the valve face would result in a knife edge, replace the valve.



11. Inspect the valve face for burning, pitting, or cracking (1, 2, 3, 4). If pieces of the valve face are broken off, replace the valve and inspect the corresponding piston and cylinder head area for damage.



12. Measure the valve stem clearance:

12.1.

Insert the valve into the guide.

12.2.

Lift the valve 2 mm (1/8 in) off of the seat.

12.3.

Move the valve from side to side.

12.4.

Use J 8001 set to measure the amount of movement.

The intake valve stem clearance should be between 0.031-0.071 mm (0.0012-0.0028 in).

The exhaust valve stem clearance should be between 0.036-0.074 mm (0.0014-0.0029 in).





Note: Clean the valve guide before reaming to avoid breaking the reamer flutes. Do not push down on the reamer.

13. Ream the valve guides for oversize valves if the clearance exceeds the specifications.
14. Ream the valve guide bores for the oversize valves.
15. Recondition the valve seats after reaming the valve guide bores or installing the new valve guides.



16. Inspect the valve stem for straightness. Use V blocks to inspect the valve head for bending or distortion. Replace any bent or distorted valves.

•	It is essential that the valve guide bores are free of carbon or dirt to ensure the proper centering of the pilot in the guide.

The valve seats should be concentric to within 0.05 mm (0.031 in) total indicator reading.

•	Reface pitted valves on a valve refacing machine to ensure the correct relationship between the valve head and the valve stem.

•	Replace the valve if the valve stem is warped (2), or if the valve stem shows signs of excessive wear.

•	Inspect the valve key area (1) for damage and carbon build up.

•	Replace the valve if the edge of the head is less than 0.79 mm (0.031 in) thick after grinding.

•	Use the manufacturer's recommendations of equipment for the proper results.