Special Tools

1. Make the valve guide hole using EN 46570  (2). Before installing the new valve guide into the cylinder head, ream the guide hole with the 11 mm reamer to remove burrs. Make sure the guide hole cones to a complete roundness (1).




Caution: Heat the cylinder head uniformly at a temperature 80-100°C (176-212°F) in order not to deform the cylinder head. Drive the new valve guide completely into the cylinder head with the valve guide installer.

2. Peen and install the new valve guide using the EN 46573  (2).

Note: Once disassembled, do not reuse the valve guide. Replace it with the new oversized valve guide.

3. Inspect 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).




4. Repair the valve guide bore with the EN 46597  (2).

Specification
The valve guide bore width is 5 mm (0.1969 in).

5. Remove any debris from the hole.



6. Install the valve spring seats.

Caution: Tapping or hitting the tool may cause damage to the seal.

Note: Do not reuse the disassembled oil seal. Replace the disassembled oil seal with a new one.

Note: When installing the new oil seal, knee tap or hit the tool with a hammer.

7. Install the seal to the guide only by pushing the special tool by hand.
8. Install the valve stem oil seal to the valve guide. After applying engine oil to the seal and installing the seal to the valve guide, make sure the seal is properly fixed to the valve guide.




Note: Before installing the valve, coat the stem seal, valve guide, and valve stem with engine oil.

9. Install the valve (1) to the valve guide.




Warning: Valve springs can be tightly compressed. Use care when removing the retainers and plugs. Personal injury could result.

10. Install the valve springs (2) and the spring retainers (1).
11. Using the EN 46569 and EN 46353 , compress the valve spring.
12. Install the valve keepers.



13. Install the camshaft front oil seal from the housing hole.



14. Coat the camshaft front oil seal, the cam, and the camshaft journal with the engine oil.
15. Install the camshaft front oil seal to the housing hole.

Caution: Use extreme care when installing the camshaft not to nick, scratch, or damage the camshaft lobes or bearing surfaces.

16. Install the camshaft to the cylinder head.

Caution: Refer to Fastener Caution in the Preface section.




17. Install the screws with the camshaft thrust plate and tighten to 10 N·m (89 lb in).



18. Coat the rocker arms and the rocker arm shafts with the engine oil.
19. Install the rocker arm spring and the rocker arm.




Note: The rocker arm shaft for the intake valves and the exhaust valves are different and their directions of installation are different.

20. Install the rocker arm shaft mounting bolts and tighten to 10 N·m (89 lb in).



21. Install the intake manifold studs.
22. Install the intake manifold with the gasket.
23. Install the intake manifold.




Note: Before tightening the intake manifold nuts, tighten the intake manifold support bracket nut.

24. Install the intake manifold nuts in the sequential order shown. Tighten the intake manifold nuts and the bolts to 17 N·m (13 lb ft) and the intake manifold bracket bolt to 10 N·m (89 lb in).



25. Install the spark plugs.



26. Install the exhaust manifold gasket and the exhaust manifold.



27. Install the bolts and nuts in the sequential order shown and tighten to 22 N·m (16 lb ft).



28. Install the exhaust manifold heat shield (1).
29. Install the exhaust manifold heat shield bolts and tighten to 10 N·m (89 lb in).



30. Install the water outlet case.
31. Install the water outlet case mounting bolts and tighten to 10.5 N·m (93 lb in).
32. Install the cylinder head with the intake manifold and exhaust manifold attached. Refer to Cylinder Head Replacement.