Disassembly and Assembly: Disassembly
- Remove the following parts:
- Intake manifold collector: Refer to "EXPLODED VIEW ".
- Fuel tube and fuel injector assembly: Refer to "EXPLODED VIEW ".
- Intake manifold: Refer to "EXPLODED VIEW ".
- Rocker cover and spark plug: Refer to "EXPLODED VIEW ".
- Exhaust manifold: Refer to "EXPLODED VIEW ".
- Water inlet and thermostat assembly: Refer to "EXPLODED VIEW ".
- Water outlets (front and rear), water pipe and heater pipe: Refer to "EXPLODED VIEW ".
- Timing chain: Refer to "EXPLODED VIEW ".
- Rear timing chain case: Refer to "EXPLODED VIEW ".
- Camshaft: Refer to "EXPLODED VIEW ".
- Remove cylinder head.
- Loosen cylinder head bolts in reverse order as shown in the figure with cylinder head bolt wrench (commercial service tool) and power tool.
- Remove cylinder head gaskets.
- Remove valve lifter.
- Identify installation positions, and store them without mixing them up.
- Remove valve collet.
- Compress valve spring with the valve spring compressor [SST: KV10116200 (J-26336-A)] (A), the attachment [SST: KV10115900 (J-26336-20)] (C) and the adapter [SST: KV10109220 (-)] (B). Remove valve collet with a magnet hand.CAUTION: When working, take care not to damage valve lifter holes.
- Compress valve spring with the valve spring compressor [SST: KV10116200 (J-26336-A)] (A), the attachment [SST: KV10115900 (J-26336-20)] (C) and the adapter [SST: KV10109220 (-)] (B). Remove valve collet with a magnet hand.
- Remove valve spring retainer, valve spring and valve spring seat.
- Push valve stem to combustion chamber side, and remove valve.
- Identify installation positions, and store them without mixing them up.
- Remove valve oil seal using the valve oil seal puller [SST: KV10107902 (J-38959)] (A).
- Remove valve seat, if valve seat must be replaced.
- Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this. Refer to
"CYLINDER HEAD ".CAUTION: Prevent to scratch cylinder head by excessive boring.
- Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this. Refer to
"CYLINDER HEAD ".
- Remove valve guide, if valve guide must be replaced.
- To remove valve guide, heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil (A).
- Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 Imp ton) pressure] or a hammer and the valve guide drift (commercial service tool).WARNING: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
- Remove spark plug tube, if necessary.
- Using a pliers, pull spark plug tube out of cylinder head.CAUTION:
- Take care not to damage cylinder head.
- Once removed, spark plug tube will be deformed and cannot be reused. Never remove it unless absolutely necessary.
- Using a pliers, pull spark plug tube out of cylinder head.