Valve Clearance Inspection
- Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter.
Valve Clearance Adjustment
- Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter.
Valve Removal
- Remove cylinder head (See Cylinder Head Removal).
- Remove the valve lifter and shim.
Mark and record the valve lifter and shim locations so they can be installed in their original positions.
- Using the valve spring compressor assembly, remove the valve.
Special Tools - Valve Spring Compressor Assembly [A]: 57001-241
Valve Spring Compressor Adapter, ∅21 [B]: 57001-1272
Valve Installation
- Replace the oil seal with a new one.
Apply engine oil to the oil seal lip.
- Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation.
- Install the springs so that the closed coil end faces downwards (the side painted in green faces upwards).
- Valve Stem [A]
- Oil Seal [B]
- Spring Seat [C]
- Closed Coil End [D]
- Valve Spring [E]
- Side Painted in Green [F]
- Retainer [G]
- Split Keepers [H]
Valve Guide Removal
Remove:
- Valve (See Valve Removal)
- Oil Seal
- Spring Seat
- Heat the area around the valve guide to 120-150°C (248-302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head.
Caution: Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head in oil and heat the oil.
Special Tool - Valve Guide Arbor, 4.5: 57001-1331
Valve Guide Installation
- Apply engine oil to the valve guide outer surface before installation.
- Heat the area around the valve guide hole to about 120-150°C (248-302°F).
- Drive the valve guide in from the top of the head using the valve guide arbor. The flange stops the guide from going in too far.
Special Tool - Valve Guide Arbor, 4.5: 57001-1331
- Wait until the cylinder head cools down and then ream the valve guide with the valve guide reamer [A] even if the old guide is reused.
Turn the reamer in a clockwise direction until the reamer turns freely in the guide. Never turn the reamer counterclockwise or it will be dulled.
Once the guides are reamed they must be cleaned thoroughly.
Special Tool - Valve Guide Reamer, ∅4.5: 57001-1333
Valve-to-Guide Clearance Measurement (Wobble Method)
If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below.
- Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
- Move the stem back and forth [C] to measure valve/valve guide clearance.
- Repeat the measurement in a direction at a right angle to the first.
If the reading exceeds the service limit, replace the guide
Note: The reading is not actual valve/valve guide clearance because the measuring point is above the guide.
Valve/Valve Guide Clearance (Wobble Method)
Standard:
- Exhaust 0.07-0.14 mm (0.0028-0.0055 in.)
- Inlet 0.02-0.08 mm (0.0008-0.0032 in.)
Service Limit:
- Exhaust 0.27 mm (0.0106 in.)
- Inlet 0.22 mm (0.0087 in.)
Valve Seat Inspection
- Remove the valve (See Valve Removal).
- Check the valve seating surface [A] between the valve [B] and valve seat [C].
Measure the outside diameter [D] of the seating pattern on the valve seat.
If the outside diameter is too large or too small, repair the seat (See Valve Seat Repair).
Valve Seating Surface Outside Diameter
Standard:
- Exhaust 27.6-27.8 mm (1.087-1.094 in.)
- Inlet 32.6-32.8 mm (1.283-1.291 in.)
- Measure the seat width [E] of the portion where there is no build-up carbon (white portion) of the valve seat with a vernier caliper.
- Good [F]
If the width is too wide [G], too narrow [H] or uneven [J], repair the seat (See Valve Seat Repair).
Valve Seating Surface Width
Standard:
- Exhaust 0.8-1.2 mm (0.031-0.047 in.)
- Inlet 0.5-1.0 mm (0.020-0.039 in.)
Valve Seat Repair
- Repair thevalve seat with the valve seat cutters [A].
Special Tools - Valve Seat Cutter Holder Bar [C]: 57001-1128
Valve Seat Cutter Holder, 04.5 [B]: 57001-1330
For Exhaust Valve Seat
- Valve Seat Cutter, 45° - 030: 57001-1187
- Valve Seat Cutter, 32° - 030: 57001-1120
- Valve Seat Cutter, 60° - 030: 57001-1123
For Inlet Valve Seat
- Valve Seat Cutter, 45° - 035: 57001-1116
- Valve Seat Cutter, 32° - 035: 57001-1121
- Valve Seat Cutter, 55° - 035: 57001-1247
If the manufacturer's instructions are not available, use the following procedure.
Seat Cutter Operation Care
1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil.
Note: Do not use a wire brush to remove the metal particles from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate the cutter in one hand. Do not apply too much force to the diamond portion.
Note: Prior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking to the cutter with washing oil.
5. After use, wash it with washing oil and apply thin layer of engine oil before storing.
Marks Stamped on the Cutter
The marks stamped on the back of the cutter [A] represent the following.
- 60° — Cutter angle [B]
- 377.5 — Outer diameter of cutter [C]
Operating Procedures
- Clean the seat area carefully.
- Coat the seat with machinist's dye.
- Fit a 45° cutter into the holder and slide it into the valve guide.
- Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth.
Caution: Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced.
- Measure the outside diameter of the seating surface with a vernier caliper.
If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the specified range.
- Widened Width [A] of engagement by machining with 45° cutter
- Ground Volume [B] by 32° cutter 32° [C]
- Correct Width [D]
- Ground Volume [E] by 60° or 55° cutter 60° or 55° [F]
- Measure the outside diameter of the seating surface with a vernier caliper.
If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range.
- Original Seating Surface [B]
Note: Remove all pittings of flaws from 45° ground surface. After grinding with 45° cutter, apply thin coat of machinist's dye to seating surface. This makes seating surface distinct and 32° and 60° (or 55°) grinding operation easier. When the valve guide is replaced, be sure to grind with 45° cutter for centering and good contact.
If the outside diameter [A] of the seating surface is too large, make the 32° grind described below.
If the outside diameter of the seating surface is within the specified range, measure the seat width as described below.
- Grind the seat at a 32° angle [B] until the seat outside diameter is within the specified range.
To make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide.
Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn.
Caution: The 32° cutter removes material very quickly. Check the seat outside diameter frequently to prevent overgrinding.
After making the 32° grind, return to the seat outside diameter measurement step above.
- To measure the seat width, use a vernier caliper to measure the width of the 45° angle portion of the seat at several places around the seat.
If the seat width is too narrow, repeat the 45° grind until the seat is slightly too wide, and then return to the seat outside diameter measurement step above.
If the seat width is too wide, make the 60° or 55° [A] grind described below.
If the seat width is within the specified range, lap the valve to the seat as described below.
- Grind the seat at a 60° or 55° angle until the seat width is within the specified range.
To make the 60° or 55° grind, fit 60° or 55° cutter into the holder, and slide it into the valve guide.
Turn the holder, while pressing down lightly.
After making the 60° or 55° grind, return to the seat width measurement step above.
- Correct Width [B]
- Lap the valve to the seat, once the seat width and outside diameter are within the ranges specified above.
Put a little coarse grinding compound on the face of the valve in a number of places around the valve head.
Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the seat and the valve.
Repeat the process with a fine grinding compound.
- Lapper [A]
- Valve Seat [B]
- Valve [C]
- The seating area should be marked about in the middle of the valve face.
If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much; replace it.
- B sure to remove all grinding compound before assembly.
- When the engine is assembled, be sure to adjust the valve clearance (See Valve Clearance Adjustment in the Periodic Maintenance chapter
