Note: Before installing the new valve guide into the cylinder head, ream guide hole with 11 mm reamer to remove burrs. Make sure that the guide hole cones to a complete roundness (1).
- Make the valve guide hole using a
EN 46570
.
- Heat the cylinder head uniformly at a temperature 80-100°C (176-212°F) not to make the head deformed, and drive new valve guide completely into the hole
with the tools the
EN 46598
(1) and the
EN 46573
(2).
Note: Do not reuse the valve guide once disassembled, replace it with the new oversized valve guide.
- Peen and install new valve guide (3).
- After installation, check the protruded part of the guide from the cylinder head (a).
Specifications
| • | The valve guide oversize is 0.03 mm (0.0012 in). |
| • | The valve guide protrusion is 14 mm (0.5512 in). |
- Repair the valve guide bore with the
EN 46597
.
- Make the hole free from foreign material.
- Install the valve spring seats (1).
Note: Do not reuse the disassembled oil seal and replace it with new one. When installing it, never tap or hit tool with a hammer or else. Install seal to guide only by pushing special tool with hand. Tapping or hitting tool may cause
damage on seal.
- Install new valve stem oil seal to the valve guide (2).
Note: After applying engine oil to seal and installing seal to the valve guide and make sure that seal is properly fixed to the valve guide.
Note: Before installing it, coat engine oil to the stem seals, valve guide bore and valve stem.
- Install the valve to the valve guide (1).
- Install the valve springs (2).
- Each valve spring has top end, large-pitch end (4) , bottom end and small-pitch end (5). Be sure to position spring in place with its bottom end down to valve spring seat side (3).
- Install the valve spring retainers (1).
Warning: Refer to Battery Disconnect Warning in the Preface section.
Note: Coat engine oil to the valve stem oil seals, the valve guide hole, and the valve stem.
- Using the
EN 46569
(1) with the
EN 47518
(2), compress the valve springs (3).
- Install the valve keeper (4).
- Coat the engine oil to the camshaft front oil seal, the cam, and the camshaft journal.
- Install the camshaft front oil seal to the housing hole (3).
Caution: Use extreme care when installing the camshaft not to nick, scratch, or damage the camshaft lobes or bearing surfaces.
- Install the camshaft to the cylinder head (2).
Caution: Refer to Fastener Caution in the Preface section.
- Install the camshaft plate (1) and tighten to
9-12 N·m (80-106 lb in).
- Coat the engine oil to the rocker arms and the rocker arm shafts.
Note: Rocker arm shafts for the intake valves and the exhaust valves are different and their directions of installation are different.
- Install the rocker arms and the rocker arm shafts (2).
- Install the rocker arm springs and the short spring to the intake side of the No. 3 cylinder (1) and tighten the bolts to
9-12 N·m (80-106 lb in).
- Install the spark plugs.
- Install the exhaust manifold gasket and the exhaust manifold (2).
- Install the bolts and nuts (1) in the sequent order as shown in the picture and tighten to
17-27 N·m (13-20 lb ft).
- Install the intake manifold heat shield (2) and tighten the bolts to
8-12 N·m (71-106 lb in).
- Install the intake manifold gasket and the intake manifold (2).
Note: Before tightening the intake manifold nuts, first of all, tighten the intake manifold support bracket nut.
- Install the intake manifold nuts in the sequent order. Tighten the intake manifold nuts to
15-19 N·m (11-14 lb ft) and the intake manifold support bracket nut to
15-19 N·m (11-14 lb ft).
- Install the distributor case and distributor with the gasket (3) and tighten the bolt and nuts to
9-12 N·m (80-106 lb in).
- Install the intake manifold main bracket with the nuts and bolts (1). Tighten the bolts and the nut to
9-12 N·m (80-106 lb in) and then the bolt to
18-22 N·m (13-16 lb ft).
- Perform the following steps when repairing the pistons and crankshaft unit:
| 30.3. | Remove the flywheel. |
| 30.4. | Install the
OTC 1726
to the engine assembly as the figure. |
| 30.5. | Drain the engine oil from the engine. |
