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CYLINDER HEAD
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6. Remove valve oil seals using valve oil seal puller (SST).
7. If valve seat must be replaced, refer to EM-99, "
VALVE SEAT REPLACEMENT" .
8. If valve guide must be replaced, refer to EM-97, "
VALVE GUIDE REPLACEMENT" .
9. Remove spark plug tube, as necessary.
Using pair of 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. Do not remove it unless
absolutely necessary.
ASSEMBLY
1. When valve guide is removed, install it. Refer to EM-97, "VALVE GUIDE REPLACEMENT" .
2. When valve seat is removed, install it. Refer to EM-99, "
VALVE SEAT REPLACEMENT" .
3. Install valve oil seals.
Install with valve oil seal drift (SST) to match dimension in the
figure.
4. Install valve spring seat.
5. Install valves.
NOTE:
Larger diameter valves are for intake side.
6. Install valve spring (uneven pitch type).
Install narrow pitch end (paint mark) to cylinder head side
(valve spring seat side).
7. Install valve spring retainer.
PBIC0884E
Height “H” (Without valve spring seat installed)
Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)
PBIC0802E
Paint mark color : Yellowish green
SEM085D
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EM-96
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8. Install valve collet.
Compress valve spring with valve spring compressor, attach-
ment and adapter (SST). Install valve collet with magnet
hand.
CAUTION:
When working, take care not to damage valve lifter holes.
Tap valve stem edge lightly with plastic hammer after installa-
tion to check its installed condition.
9. Install valve lifter.
Install it in the original position.
10. Install spark plug tube.
Press-fit spark plug tube as follows:
a. Remove old liquid gasket adhering to cylinder head mounting hole.
b. Apply liquid gasket to area within approximately 12 mm (0.47 in) from edge of spark plug tube press-fit
side.
Use Genuine High Strength Locking Sealant or equivalent. Refer to GI-45, "
RECOMMENDED
CHEMICAL PRODUCTS AND SEALANTS" .
c. Using drift, press-fit spark plug tube so that its height “H” is as
specified in the figure.
CAUTION:
When press-fitting, take care not to deform spark plug
tube.
After press-fitting, wipe off liquid gasket protruding onto
cylinder-head upper face.
11. Install spark plug with spark plug wrench (commercial service
tool).
Inspection After DisassemblyNBS00011
VALVE DIMENSIONS
Check dimensions of each valve. For dimensions, refer to EM-
139, "Valve Dimensions" .
If dimensions are out of the standard, replace valve and check
valve seat contact. Refer to EM-99, "
VALVE SEAT CONTACT" .
PBIC1803E
Standard press-fit height “H”:
: 37.7 - 38.7 mm (1.484 - 1.524 in)
PBIC2638E
SEM188A
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EM-100
CYLINDER HEAD
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6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact. Refer to EM-99, "
VALVE SEAT CONTACT" .
VALVE SPRING SQUARENESS
Set try square along the side of valve spring and rotate spring.
Measure the maximum clearance between the top face of spring
and try square.
If it exceeds the limit, replace valve spring.
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD
Check valve spring pressure at specified spring height.
If the installation load or load with valve open is out of the standard, replace valve spring.Limit: : 1.9 mm (0.075 in)
PBIC0080E
Standard:
Intake and exhaust
Free height : 43.85 mm (1.7264 in)
Installation height : 37.0 mm (1.457 in)
Installation load : 166 – 188 N
(16.9 – 19.2 kg, 37 – 42 lb)
Height during valve open : 26.8 mm (1.055 in)
Load with valve open : 502 – 566 N
(51.2 – 57.7 kg, 113 – 127 lb)
SEM113
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CYLINDER BLOCK
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Remove lower cylinder block and bearings, and using scale on
plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
CRUSH HEIGHT OF MAIN BEARING
When lower cylinder block is removed after being tightened to
the specified torque with main bearings installed, the tip end of
bearing must protrude. Refer to E M - 111 , "
ASSEMBLY" for the
tightening procedure.
If the standard is not met, replace main bearings.
CRUSH HEIGHT OF CONNECTING ROD BEARING
When connecting rod bearing cap is removed after being tight-
ened to the specified torque with connecting rod bearings
installed, the tip end of bearing must protrude. Refer to E M - 111 ,
"ASSEMBLY" for the tightening procedure.
If the standard is not met, replace connecting rod bearings.
LOWER CYLINDER BLOCK BOLT OUTER DIAMETER
Measure the outer diameters (“d1 ”, “d2 ”) at two positions as
shown in the figure.
If reduction appears in “A” range, regard it as “d2 ”.
If it exceeds the limit (large difference in dimensions), replace
lower cylinder block bolt with new one.
PBIC1149E
Standard : There must be crush height.
SEM502G
Standard : There must be crush height.
PBIC1646E
Limit (“d1 ” – “d2 ”) : 0.11 mm (0.0043 in)
PBIC0911E
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SERVICE DATA AND SPECIFICATIONS (SDS)
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SPARK PLUG
Unit: mm (in)
CAMSHAFT AND CAMSHAFT BEARING
Unit: mm (in)
*
1 : Cam wear limit
*2 : Total indicator reading
Valve Lifter
Unit: mm (in)
Valve Clearance
Unit: mm (in)
*: Approximately 80°C (176°F) MakeDENSO
Standard typeFXE22HR11
Gap (Nominal)1.1 (0.043)
Items Standard Limit
Camshaft journal oil clearanceNo. 1 0.045 - 0.086 (0.0018 - 0.0034)
0.15 (0.0059)
No. 2, 3, 4 0.035 - 0.076 (0.0014 - 0.0030)
Camshaft bracket inner diameterNo. 1 26.000 - 26.021 (1.0236 - 1.0244) —
No. 2, 3, 4 23.500 - 23.521 (0.9252 - 0.9260) —
Camshaft journal diameterNo. 1 25.935 - 25.955 (1.0211 - 1.0218) —
No. 2, 3, 4 23.445 - 23.465 (0.9230 - 0.9238) —
Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094)
Camshaft cam height “A”Intake 45.865 - 46.055 (1.8057 - 1.8132)
0.2 (0.008)*
1
Exhaust 45.875 - 46.065 (1.8061 - 1.8136)
Camshaft runout (TIR*
2 )Less than 0.02 (0.0008) 0.05 (0.0020)
Camshaft sprocket runout (TIR*
2 )— 0.15 (0.0059)
SEM671
Items Standard
Valve lifter outer diameter 33.980 - 33.990 (1.3378 - 1.3382)
Valve lifter hole diameter 34.000 - 34.016 (1.3386 - 1.3392)
Valve lifter clearance0.010 - 0.036 (0.0004 - 0.0014)
Items Cold Hot* (reference data)
Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)
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SERVICE DATA AND SPECIFICATIONS (SDS)
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CYLINDER HEAD
Unit: mm (in)
Valve Dimensions
Unit: mm (in) Items Standard Limit
Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
Normal cylinder head height “H” 126.3 - 126.5 (4.972 - 4.980) —
PBIC0924E
Valve head diameter “D”Intake 36.6 - 36.9 (1.441 - 1.453)
Exhaust 30.2 - 30.5 (1.189 - 1.201)
Valve length “L”Intake 97.13 (3.8240)
Exhaust 94.67 (3.7272)
Valve stem diameter “d”Intake 5.965 - 5.980 (0.2348 - 0.2354)
Exhaust 5.962 - 5.970 (0.2347 - 0.2350)
Valve seat angle “α”Intake
45°15′ - 45°45′
Exhaust
Valve margin “T”Intake 1.1 (0.043)
Exhaust 1.3 (0.051)
Valve margin “T” limit0.5 (0.020)
Valve stem end surface grinding limit 0.2 (0.008)
SEM188
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SERVICE DATA AND SPECIFICATIONS (SDS)
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Valve Seat
Unit: mm (in)
*
1 : Diameter made by intersection point of conic angles “α1” and “α2”
*2 : Diameter made by intersection point of conic angles “α2” and “α3”
*3 : Machining data
Valve Spring
Unit: mm (in) Items Standard Oversize (Service) [0.5 (0.02)]
Cylinder head seat recess diameter “D”Intake 38.000 - 38.016 (1.4961 - 1.4967) 38.500 - 38.516 (1.5157 - 1.5164)
Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644)
Valve seat outer diameter “d”Intake 38.097 - 38.113 (1.4999 - 1.5005) 38.597 - 38.613 (1.5196 - 1.5202)
Exhaust 31.680 - 31.696 (1.2472 - 1.2479) 32.180 - 32.196 (1.2669 - 1.2676)
Valve seat interference fitIntake 0.081 - 0.113 (0.0032 - 0.0044)
Exhaust 0.064 - 0.096 (0.0025 - 0.0038)
Diameter “d1”*
1Intake 34.6 (1.36)
Exhaust 27.7 (1.091)
Diameter “d2”*
2Intake 35.9 - 36.4 (1.413 - 1.433)
Exhaust 29.3 - 29.8 (1.154 - 1.173)
Angle “α1”Intake 60°
Exhaust 60°
Angle “α2”Intake 88°45′ - 90°15′
Exhaust 88°45′ - 90°15′
Angle “α3”Intake 120°
Exhaust 120°
Contacting width “W”*
3Intake 1.0 - 1.4 (0.039 - 0.055)
Exhaust 1.2 - 1.6 (0.047 - 0.063)
Height “h”Intake 5.9 - 6.0 (0.232 - 0.236) 5.05 - 5.15 (0.1988 - 0.2028)
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988)
Depth “H”6.0 (0.236)
PBIC2745E
Items
Free height43.85 (1.7264)
Installation height 37.00 (1.4567)
Installation load 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb)
Height during valve open 26.8 (1.0551)
Load with valve open 502 - 566 N (51.2 - 57.7 kg, 113 - 127 lb)
squareness1.9 (0.075)