Page 89 of 1771

Valve Seat s
Reconditionin g
1. Rene w th e valv e seat s i n th e cylinde r hea d usin g a
valv e sea t cutter .
NOTE : I f th e guide s ar e wor n (se e pag e 6-28 ), replac e
the m (se e pag e 6-30 ) befor e cuttin g th e valv e seats .
2.
3.
4 .
VALV E SEA TCUTTE R(Commerciall y available )
Carefully cu t a 45 ° seat , removin g onl y enoug h
materia l t o ensur e a smoot h an d concentri c seat .
Beve l th e uppe r edg e o f th e sea t wit h th e 30 ° cutte r
an d th e lowe r edg e o f th e sea t wit h th e 60 ° cutter .
Chec k th e widt h o f th e sea t an d adjus t accordingly .
Mak e on e mor e ver y ligh t pas s wit h th e 45 ° cutte r t o
remov e an y possibl e burr s cause d b y th e othe r cut -
ters .
Valv e Sea t Width :
Standar d (New) : Intak e 0.8 0 - 1.0 0 m m
(0.03 1 - 0.03 9 in )
Exhaus t 1.2 5 - 1.5 5 m m
(0.04 9 - 0.06 1 in )
Servic e Limit : Intak e 2. 0 m m (0.0 8 in )
Exhaus t 2. 0 m m (0.0 8 in )
SEA T WIDT H
5.
6.
7 .
8.
Afte r resurfacin g th e seat , inspec t fo r eve n valv e
seating : Appl y Prussia n Blu e compoun d t o th e valv e
face , an d inser t th e valv e i n it s origina l locatio n i n
th e head , the n lif t i t an d sna p i t close d agains t th e
sea t severa l times .
ACTUA LSEATIN GSURFAC E
VALVESEAT
PRUSSIA N BLU E COMPOUN D
The actua l valv e seatin g surface , a s show n b y th e
blu e compound , shoul d b e centere d o n th e seat .
I f i t i s to o hig h (close r t o th e valv e stem) , yo u
mus t mak e a secon d cu t wit h th e 60 ° cutte r t o
mov e i t down , the n on e mor e cu t wit h th e 45 °
cutte r t o restor e sea t width .
I f i t i s to o lo w (close r t o th e valv e edge) , yo u
mus t mak e a secon d cu t wit h th e 30 ° cutte r t o
mov e it up , the n on e mor e cu t wit h th e 45 ° cutte r
t o restor e sea t width .
NOTE : Th e fina l cu t shoul d alway s b e mad e wit h
the 45 ° cutter .
Insert th e intak e an d exhaus t valve s i n th e hea d an d
measur e th e valv e ste m installe d height .
Valv e Ste m Installe d Height :
Standar d (New) : Intak e 46.93 5 - 47.42 5 m m
(1.8478-1.867 1 in )
Exhaus t 47.88 5 - 48.37 5 m m
(1.8852-1.904 5 in )
Servic e Limit : Intak e 47.62 5 m m (1.875 0 in )
Exhaus t 48.57 5 m m (1.912 4 in )
VALV E STE MINSTALLE D HEIGH T
If valv e ste m installe d heigh t i s ove r th e servic e limit ,
replac e th e valv e an d recheck . I f i t i s stil l ove r th e ser -
vic e
limit , replac e the cylinde r head ; the valv e sea t in
th e hea d is to o deep .
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Page 90 of 1771

Valve Guide s
Replacemen t
1. As illustrate d below , us e a commerciall y - availabl e
air-impac t valv e guid e drive r attachmen t modifie d t o
fit th e diameter of th e valv e guides . I n mos t cases ,
th e sam e procedur e ca n b e don e usin g th e specia l
too l an d a conventiona l hammer .
VALVE GUID E DRIVE R(Commerciall y available )
VALVE GUID E DRIVER , 5. 5 m m07742-001010 0
2. Selec t th e prope r replacemen t guide s an d chil l the m
i n th e freeze r sectio n o f a refrigerato r fo r abou t a n hour .
3 . Us e a ho t plat e o r ove n t o evenl y hea t th e cylinde r
hea d t o 300° F (150°C) . Monito r th e temperatur e wit h
a cookin g thermometer .
CAUTION :
D o no t us e a torch ; i t ma y war p th e head .
D o no t ge t th e hea d hotte r tha n 300° F (150°C) ;
excessiv e hea t ma y loose n th e valv e seats .
T o avoi d burns , us e heav y glove s whe n handlin g
th e heate d cylinde r head . 4
. Workin g fro m th e camshaf t side , us e th e drive r an d a n
ai r hamme r t o driv e th e guid e abou t 2 m m (0. 1 in )
toward s th e combustio n chamber . Thi s wil l knoc k of f
som e o f th e carbo n an d mak e remova l easier .
CAUTION :
Alway s wea r safet y goggle s o r a fac e shiel d
whe n drivin g valv e guides .
Hol d th e ai r hamme r directl y i n lin e wit h th e
valv e guid e to preven t damagin g th e driver .
5 . Tur n th e hea d ove r an d driv e th e guid e ou t towar d
th e camshaf t sid e o f th e head .
VALV E GUID E DRIVER , 5. 5 m m0774 2 - 001010 0
6.
If a valv e guid e stil l won' t move , dril l i t ou t wit h a
8 m m (5/1 6 in ) bit , the n tr y again .
CAUTION : Dril l guide s onl y in extrem e cases : yo u
coul d damag e th e cylinde r hea d if th e guid e breaks .
Remov e th e ne w guide s fro m th e freezer , on e a t a
time , a s yo u nee d them .
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Page 91 of 1771
7. Appl y a thi n coa t o f clea n engin e oi l t o th e outsid e o f
th e ne w valv e guide . Instal l th e guid e fro m th e
camshaf t sid e o f th e head ; us e th e specia l too l t o
driv e th e guid e i n t o th e specifie d installe d height . I f
yo u hav e al l 1 2 guide s to do , yo u ma y hav e to rehea t
th e head .
VALV E GUID E
DRIVER , 5. 5 m m
0774 2 — 001010 0
Valve Guid e Installe d Height :
Intake : 15.7 5 - 16.2 5 m m (0.62 0 - 0.64 0 in )
Exhaust : 15.7 5 - 16.2 5 m m (0.62 0 - 0.64 0 in )
VALV E GUID E
Measure here .
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Page 92 of 1771
Reaming
NOTE: Fo r ne w valv e guide s only .
1 . Coa t bot h th e reame r an d valv e guid e wit h cuttin g
oil.
2. Rotat e th e reame r clockwis e th e ful l lengt h o f th e
valv e guid e bore .
3 . Continu e t o rotat e th e reame r clockwis e whil e
removin g i t fro m th e bore .
4 . Thoroughl y was h th e guid e i n detergen t an d wate r
t o remov e an y cuttin g residue .
5 . Chec k th e clearanc e wit h a valv e (se e pag e 6-28 ).
— Verif y tha t a valv e slide s i n th e valv e guid e with -
ou t exertin g pressure .
REAMER HANDL E
VALVE GUID E
REAMER , 5. 5 m m
07HA H - PJ7010 B
Tur n reame r i n
clockwis e directio n
only.
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Page 93 of 1771
Valves, Valve Springs and Valve Seals
Installation Sequence
NOTE: Exhaust and intake valve seals are NOT interchangeable.
VALVE SPRING
NOTE: Place the end of the valve
spring with closely wound coils
toward the cylinder head.
INTAKE VALVE SEAL
(WHITE SPRING)
Replace.
VALVE KEEPERS
VALVE SPRING
RETAINER
EXHAUST VALVE SEAL
(BLACK SPRING)
Replace.
SPRING SEAT
NOTE: Install the valve spring seats
before installing the valve seals.
VALVE GUIDE SEAL INSTALLER
KD - 2899 or EQUIVALENT
(Commercially available)
NOTE: Use the end
of the tool with the
smallest I.D.
VALVE SEAL
Replace.ProCarManuals.com
Page 94 of 1771

Hydraulic Tappets
Valve Installation
When installing valves in the cylinder head, coat the
valve stems with oil before inserting them into the valve
guides. Make sure the valves move up and down
smoothly.
When the valves and springs are in place, lightly tap the
end of each valve stem two or three times with a plastic
mallet to ensure proper seating of the valve and valve
keepers.
NOTE:
Make sure that the valve keepers are properly posi-
tioned on the valve stem.
Tap the valve stem only along its axis so you do not
bend the stem.
PLASTIC MALLET
Bleeding
VALVE STEM ENDS
1. Fill a container with 10W - 30 engine oil and place
the hydraulic tappet in it. Press down on the check
ball with a thin wire. Bleed the tappet of air by
pumping the plunger slowly until no bubbles come
out of the hydraulic tappet.
WIRE
PLUNGER
10W —30
ENGINE OIL
HYDRAULIC
TAPPET
CHECK BALL
2. Install the hydraulic tappet to the rocker arm.
NOTE:
Use a new O-ring when reassembling.
Apply oil to the O-ring before installation.
ROCKER ARM
O-RING
Replace.
HYDRAULIC
TAPPETProCarManuals.com
Page 95 of 1771

Camshafts/Rocker Arms and Camshaft Seals
Installation
CAUTION:
Make sure that all rockers are in alignment with their
valves when torquing the rocker assembly bolts.
To prevent the rocker arm assembly from coming
apart, leave the camshaft holder bolts in the holes.
Handle the rocker arms carefully so that the oil does
not come out of the hydraulic tappets.
1.
2.
Install the camshaft and rubber cap, then install the
camshaft seal with the open side (spring) facing in.
NOTE:
Position the camshaft with pin hole at the top.
Do not apply oil to the camshaft holder mating
surface of the camshaft seal.
Apply liquid gasket around the rubber cap.
RUBBER CAP
Replace if there was
oil leakage.
CAMSHAFT
OIL SEAL
Replace.
Seal housing surface should be dry.
Apply a light coat of oil to camshaft
and inner lip of seal.
Engine No. 1300001~1309262 (U.S.A.), 1700001~
1700751 (Canada):
Apply liquid gasket to the head mating surfaces of
the No. 1 and the No. 7 camshaft holders.
Engine No. 1309263~, 2300001 ~, 3300001~ (U.S.A.),
1700752~, 2700001 ~, 3700001~ (Canada):
Apply liquid gasket to the head mating surfaces of
the No. 1 and the No. 5 camshaft holders.
— Apply liquid gasket to the shaded areas.
3. Tighten each bolt two turns at a time in the sequence
shown below to ensure that the rockers do not bind
on the valves.
Specified torque:
8 mm bolts: 22 N-m (2.2 kgf-m, 16 Ibf-ft)
6 mm bolts: 12 N-m (1.2 kgf-m, 8.7 Ibf-ft)
Engine No. 1300001~1309262 (U.S.A.), 1700001~
1700751 (Canada):
6 mm bolts:
Engine No. 1309263~, 2300001 ~, 3300001~ (U.S.A.),
1700752~, 2700001 ~. 3700001~ (Canada):
8 mm bolts:ProCarManuals.com
Page 96 of 1771

Cylinder Heads
Installation
Install th e cylinde r head s in th e revers e orde r o f removal .
NOTE:
Alway s us e ne w cylinde r hea d gaskets .
Cylinde r head s an d cylinde r bloc k surfac e mus t b e
clean .
Turn th e camshaft s s o th e pulle y locatin g pi n hole s
are a t th e top .
Turn th e crankshaf t s o th e No . 1 pisto n is a t TD C (se e
pag e 6-8 ).
Clea n th e oi l contro l orifice s befor e installing .
D o no t us e th e uppe r an d lowe r cover s t o stor e
remove d item .
Clea n th e uppe r an d lowe r cover s befor e installation .
1 . Alig n th e cylinde r hea d dowe l pins .
2 . Instal l th e oi l contro l orifice s an d cylinde r hea d gas -
kets.
RIGH T CYLINDE RHEAD GASKE T("R" MARK )
OIL CONTRO LORIFICESRemove wit h 6 x 1. 0 m m
bol t an d clean .
OIL CONTRO LORIFICEClean.O-RING SReplace .
DOWELPINS
LEF T CYLINDE RHEAD GASKE TReplace.
3. Appl y clea n engin e oi l t o th e thread s o f th e cylinde r
hea d bolts . 4
. Instal l th e cylinde r head s o n th e cylinde r block .
5. Tighte n th e cylinde r hea d bolt s sequentiall y in tw o
or thre e steps .
Specifie d Torque :
7 6 N- m (7. 8 kgf-m , 5 6 Ibf-ft )
NOTE :
We recommen d usin g a beam-typ e torqu e wrench .
Whe n usin g a preset-typ e torqu e wrench , b e sur e
t o tighte n slowl y an d no t t o overtighten .
I f a bol t make s an y nois e whil e yo u ar e torquin g
it , loose n th e bolt , an d retighte n it .
CYLINDE R HEA D BOLT S TORQU E SEQUENC E
CYLINDER HEA D BOLT SApply engin e oi l t o th e bol tthreads .
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