Disassembly and Assembly: Assembly

Replace with oversized [0.2 mm (0.008 in)] valve guide (EXH).

1. Using the valve guide reamer (commercial service tool) (A), ream cylinder head valve guide (EXH) hole.

   Oversize (service) [0.2 mm (0.008 in)]: 

   : Refer to  "CYLINDER HEAD ".

   Fig 1: Reaming Cylinder Head Valve Guide (EXH) Hole Using Valve Guide Reamer

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2. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil (A).
   Fig 2: Heating Cylinder Head Using Heated Oil

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3. Using the valve guide drift (commercial service tool), press valve guide (EXH) from camshaft side to the dimensions as shown in the figure below.

   Projection (A) 

   : Refer to  "CYLINDER HEAD ".

   Fig 3: Identifying Valve Guide (EXH) Installation Dimension

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   WARNING: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
4. Using the valve guide reamer (commercial service tool) (A), apply reamer finish to valve guide (EXH).

   Standard: Refer to  "CYLINDER HEAD ".

   Fig 4: Reaming Cylinder Head Valve Guide (EXH) Hole Using Valve Guide Reamer

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Replace with oversize [0.5 mm (0.020 in)] valve seat (EXH).

1. Ream cylinder head recess diameter (a) for service valve seat (EXH).

   Oversize (service) [0.5 mm (0.020 in)]: 

   : Refer to  "CYLINDER HEAD ".

   • Be sure to ream in circles concentric to valve guide center.

   This enables valve to fit correctly.

   Fig 5: Identifying Cylinder Head Recess Diameter

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2. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil (A).
   Fig 6: Heating Cylinder Head Using Heated Oil

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3. Provide valve seats (EXH) cooled well with dry ice. Force fit valve seat (EXH) into cylinder head.
   WARNING: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
   CAUTION: Avoid directly touching cold valve seats.
4. Using the valve seat cutter set (commercial service tool) or valve seat grinder, finish seat to the specified dimensions. Refer to "CYLINDER HEAD ".
   CAUTION: When using the valve seat cutter, firmly grip cutter handle with both hands. Then, press on the contacting surface all around the circumference to cut in a single drive. Improper pressure on cutter or cutting many different times may result in staged valve seat.
   Fig 7: Finishing Valve Seat Using Valve Seat Cutter

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5. Using compound, grind to adjust valve fitting.
6. Check again for normal contact. Refer to "INSPECTION ".

1. Apply new engine oil on new valve oil seal joint and seal lip.
2. Using the valve oil seal drift [SST: KV10115600 (J-38958)] (A), press fit valve seal to height (b) shown in figure below.

   Height (b) 

   Intake: 14.3 - 14.9 mm (0.563 - 0.587 in) 

   Exhaust: 13.6 - 14.2 mm (0.535 - 0.559 in) 

   Fig 8: Pressing Valve Seal Using Drift

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• Check that the oil filter does not protrude from the upper surface of cylinder block (2) after installation.

Fig 9: Locating Oil Filter And Cylinder Block

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• Tighten cylinder head bolts in numerical order as shown in figure below.
  Fig 10: Cylinder Head Mounting Bolts Tightening Sequence

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• Use TORX socket.

1. Apply new engine oil to threads and seat surfaces of cylinder head bolts.
2. Tighten all cylinder head bolts.

   Torque Value: 40 N.m (4.1 kg-m, 30 ft-lb) 

3. Tighten all cylinder head bolts (clockwise).

   Angle tightening: 75 degrees 

4. Completely loosen all cylinder head bolts.

   Torque Value: 0 N.m (0 kg-m, 0 ft-lb) 

   CAUTION: In step "d", loosen bolts in the reverse order of that indicated in the figure.
5. Tighten all cylinder head bolts.

   Torque Value: 40.0 N.m (4.1 kg-m, 30 ft-lb) 

6. Tighten all cylinder head bolts (clockwise).

   Angle tightening: 65 degrees 

   CAUTION: Check the tightening angle using the angle wrench [SST: KV10112100 (BT8653-A)] (A). Never make judgment by visual inspection.
   • Check tightening angle indicated on the angle wrench indicator plate.
7. Tighten all cylinder head bolts again (clockwise).

   Angle tightening: 65 degrees 

   Fig 11: Checking Tightening Angle Using Angle Wrench

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• Install narrow pitch (B) end [paint mark (C)] to cylinder head side (valve spring seat side).
  Fig 12: Identifying Wide And Narrow Pitch Of Valve Spring

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  Paint mark color 

  Intake: Yellow 

  Exhaust: Pink 

• Compress valve spring with the valve spring compressor [SST:

  KV10116200 (J26336-A)] (A), the attachment [SST:

  KV10115900 (J26336-20)] (C) and the adapter [SST:

  KV10109220 (-)] (B). Install valve collet with a magnet hand.

  CAUTION: When working, take care not to damage valve lifter holes.
  Fig 13: Compressing Valve Spring Using Compressor

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• Tap valve stem edge lightly with plastic hammer after installation to check its installed condition.

• Install it in the original position.