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Special Tools Required
6-56
Cylinder Head
Valve Guide Replacement
A
5.3 mm
(0.21 in.)
10.8 mm
(0.43 in.)
87 mm
(3.43 in.)
57 mm
(2.24 in.)
Valve guide driver, 5.5 mm 07742-0010100
Valve guide reamer, 5.5 mm 07HAH-PJ7A100
1. Inspect the valve stem-to-guide clearance (see page 6-55).
2. As illustrated, use a commercially available air- impact valve guide driver (A) modified to fit the
diameter of the valve guides. In most cases, the
same procedure can be done using the valve guide
driver and a conventional hammer.
3. Select the proper replacement guides, and chill them in the freezer section of a refrigerator for at
least an hour.
4. Use a hot plate or oven to evenly heat the cylinder head to 150 °C (300 °F). Monitor the temperature
with a cooking thermometer. Do not get the head
hotter than 150 °C (300 °F); excessive heat may
loosen the valve seats. 5. Working from the camshaft side, use the driver and
an air hammer to drive the guide about 2 mm
(0.1 in.) towards the combustion chamber. This will
knock off some of the carbon and make removal
easier. Hold the air hammer directly in line with the
valve guide to prevent damaging the driver.
6. Turn the head over, and drive the guide out toward the camshaft side of the head.
7. If a valve guide won’t move, drill it out with a 8 mm (5/16 in.) bit, then try again.
NOTE: Drill guides only in extreme cases, you
could damage the cylinder head if the guide breaks.
8. Remove out the new guide(s) from the freezer, one at a time, as you need them.
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Valve Guide Installed Height
Intake: 15.2 16.2 mm (0.598 0.638 in.)
Exhaust: 15.5 16.5 mm (0.610 0.650 in.)
6-57
B
A
07742-0010100
07HAH-PJ70100
9. Apply a thin coat of new engine oil to the outside of
the new valve guide. Install the guide from the
camshaft side of the head, use the valve guide
driver to drive the guide in to the specified installed
height (A) of the guide (B). If you have all 16 guides
to do, you may have to reheat the head. 10. Coat both valve guide reamer, 5.5 mm and the
valve guide with cutting oil.
11. Rotate the reamer clockwise to the full length of the valve guide bore.
12. Continue to rotate the reamer clockwise while removing it from the bore.
13. Thoroughly wash the guide in detergent and water to remove any cutting residue.
14. Check the clearances with a valve (see page 6-55). Verify that a valve slides into the intake and
exhaust valve guides without sticking.
15. Inspect the valve seating, if necessary renew the valve seat using a valve seat cutter (see page 6-58).
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Valve Seat Width
Standard (New): 1.25 1.55 mm (0.049 0.061 in.)
Service Limit: 2.00 mm (0.079 in.)
6-58 Cylinder Head
Valve Seat Reconditioning
45 °
INTAKE: 35 °
EXHAUST: 30 °
67.5 ° A
B
1. Inspect the valve stem-to-guide clearance
(see page 6-55). If the valve guides are worn,
replace them (see page 6-56) before cutting the
valve seats.
2. Renew the valve seats in the cylinder head using a valve seat cutter.
3. Carefully cut a 45 ° seat, removing only enough material to ensure a smooth and concentric seat.
4. Bevel the upper and lower edges at the angles
shown in the illustration.
Check the width of the seat and adjust accordingly. 5. Make one more very light pass with the 45 ° cutter
to remove any possible burrs caused by the other
cutters.
6. After resurfacing the seat, inspect for even valve seating. Apply Prussian Blue compound (A) to the
valve face. Insert the valve in its original location in
the head, then lift it and snap it closed against the
seat several times.
7. The actual valve seating surface (B), as shown by the blue compound, should be centered on the seat.
If it is too high (closer to the valve stem), you must make a second cut with the 67.5 ° cutter to
move it down, then one more cut with the 45 °
cutter to restore seat width.
If it is too low (close to the valve edge), you must make a second cut with the 35 ° cutter (intake
side) or the 30 ° cutter (exhaust side) to move it
up, then make one more cut with the 45 ° cutter
to restore seat width.
NOTE: The final cut should always be made with
the 45 ° cutter.
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Intake Valve Stem Installed Height
Standard (New): 44.0 44.5 mm (1.73 1.75 in.)
Service Limit: 44.7 mm (1.76 in.)
Exhaust Valve Stem Installed Height
Standard (New): 44.1 44.6 mm (1.74 1.76 in.)
Service Limit: 44.8 mm (1.76 in.) Special Tools Required
6-596-59
Valve, Spring, and Valve Seal
Installation
A
AB
07PAD-0010000
F
D
EC
8. Insert the intake and exhaust valves in the head, and measure the valve stem installed height (A).
9. If the valve stem installed height is beyond the service limit, replace the valve and recheck. If it is
still beyond the service limit, replace the cylinder
head, the valve seat in the head is too deep. Stem seal driver 07PAD-0010000
Valve spring compressor attachment 07757-PJ1010A
1. Coat the valve stems with new engine oil. Install the valves in the valve guides.
2. Check that the valves move up and down smoothly.
3. Install the spring seats on the cylinder head.
4. Install the new valve seals (A) using the 5.5 mm side of the stem seal driver (B).
NOTE: The exhaust valve seal (C) has a black spring
(D), and the intake valve seal (E) has a white spring
(F). They are not interchangeable.
(cont’d)
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Intake Valve Stem Installed Height
Standard (New): 44.0 44.5 mm (1.73 1.75 in.)
Service Limit: 44.7 mm (1.76 in.)
Exhaust Valve Stem Installed Height
Standard (New): 44.1 44.6 mm (1.74 1.76 in.)
Service Limit: 44.8 mm (1.76 in.) Special Tools Required
6-596-59
Valve, Spring, and Valve Seal
Installation
A
AB
07PAD-0010000
F
D
EC
8. Insert the intake and exhaust valves in the head, and measure the valve stem installed height (A).
9. If the valve stem installed height is beyond the service limit, replace the valve and recheck. If it is
still beyond the service limit, replace the cylinder
head, the valve seat in the head is too deep. Stem seal driver 07PAD-0010000
Valve spring compressor attachment 07757-PJ1010A
1. Coat the valve stems with new engine oil. Install the valves in the valve guides.
2. Check that the valves move up and down smoothly.
3. Install the spring seats on the cylinder head.
4. Install the new valve seals (A) using the 5.5 mm side of the stem seal driver (B).
NOTE: The exhaust valve seal (C) has a black spring
(D), and the intake valve seal (E) has a white spring
(F). They are not interchangeable.
(cont’d)
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K20Z2 engine
6-606-60 Cylinder Head
Valve, Spring, and Valve Seal
Installation (cont’d)
Rocker Arm Assembly Installation
07757-PJ1010A
A
A A
B
5. Install the valve spring and the spring retainer.Place the end of the valve spring with the closely
wound coils toward the cylinder head.
6. Install the valve spring compressor attachment and the valve spring compressor. Compress the valve
spring, and install the valve cotters.
7. Remove the valve spring compressor and the valve spring compressor attachment.
8. Lightly tap the end of each valve stem two or three times with a plastic mallet (A) to ensure proper
seating of the valve and valve keepers. Tap the
valve stem only along its axis so you do not bend
the stem. 1. Reassemble the rocker arm assembly (see page
6-46).
2. Clean and dry the No. 5 rocker shaft holder mating surface.
3. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, evenly to the cylinder
head mating surface of the No. 5 rocker shaft
holder. Install the component within 5 minutes of
applying the liquid gasket.
NOTE: If you apply liquid gasket P/N 08718-0012, the component must be install within 4 minutes.
If too much time has passed after applying the liquid gasket, remove the old liquid gasket and
residue, then reapply new liquid gasket.
4. Insert the bolts (A) into the rocker shaft holder, then install the rocker arm assembly (B) on the cylinder
head.
Apply liquid gasket
along the broken line.
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K20Z2 engine
6-606-60 Cylinder Head
Valve, Spring, and Valve Seal
Installation (cont’d)
Rocker Arm Assembly Installation
07757-PJ1010A
A
A A
B
5. Install the valve spring and the spring retainer.Place the end of the valve spring with the closely
wound coils toward the cylinder head.
6. Install the valve spring compressor attachment and the valve spring compressor. Compress the valve
spring, and install the valve cotters.
7. Remove the valve spring compressor and the valve spring compressor attachment.
8. Lightly tap the end of each valve stem two or three times with a plastic mallet (A) to ensure proper
seating of the valve and valve keepers. Tap the
valve stem only along its axis so you do not bend
the stem. 1. Reassemble the rocker arm assembly (see page
6-46).
2. Clean and dry the No. 5 rocker shaft holder mating surface.
3. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, evenly to the cylinder
head mating surface of the No. 5 rocker shaft
holder. Install the component within 5 minutes of
applying the liquid gasket.
NOTE: If you apply liquid gasket P/N 08718-0012, the component must be install within 4 minutes.
If too much time has passed after applying the liquid gasket, remove the old liquid gasket and
residue, then reapply new liquid gasket.
4. Insert the bolts (A) into the rocker shaft holder, then install the rocker arm assembly (B) on the cylinder
head.
Apply liquid gasket
along the broken line.
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Specified Torque
8x1.25mm
22 N·m (2.2 kgf·m, 16 lbf·ft)
6x1.0mm
12 N·m (1.2 kgf·m, 8.7 lbf·ft)
6 x 1.0 mm Bolts: , ,
K20Z3 engine
6-616-61
C A B
A A
B
5. Remove the bolts from the rocker shaft holder.
6. Make sure the punch marks on the variable valvetiming control (VTC) actuator and the exhaust
camshaft sprocket are facing up, then set the
camshafts (A) in the holder. Apply new engine oil to
the camshaft journals and lobes.
7. Set the camshaft holders (C) and cam chain guide B in place.
8. Tighten the bolts to the specified torque.
9. Install the cam chain (see page 6-21), then adjust the valve clearance (see page 6-12). 1. Reassemble the rocker arm assembly (see page
6-47).
2. Clean and dry the No. 5 rocker shaft holder mating surface.
3. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, evenly to the cylinder
head mating surface of the No. 5 rocker shaft
holder. Install the component within 5 minutes of
applying the liquid gasket.
NOTE: If you apply liquid gasket P/N 08718-0012, the component must be install within 4 minutes.
If too much time has passed after applying the liquid gasket, remove the old liquid gasket and
residue, then reapply new liquid gasket.
4. Insert the bolts (A) into the rocker shaft holder, then install the rocker arm assembly (B) on the cylinder
head.
5. Remove the bolts from the rocker shaft holder. (cont’d)
Apply liquid gasket
along the broken line.
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