Part 1

DISASSEMBLY
1. REMOVE OIL PRESSURE SWITCH
2. REMOVE WATER TEMPERATURE SENSOR





3. REMOVE CAMSHAFT POSITION SENSOR
Remove the bolt and camshaft position sensor.
4. REMOVE VALVE LIFTERS HINT
Arrange the valve lifters in the correct order.
5. REMOVE VALVES





a. Using SST, compress the valve spring and remove the 2 keepers.
SST 09202-70020 (09202-00020)
b. Remove the spring retainer, valve spring and valve.





c. Using needle-nose pliers, remove the oil seal.





d. Using compressed air and a magnetic finger, remove the spring seat by blowing air.

HINT: Arrange the valves, valve springs, spring seats, and spring retainers in the correct order.

INSPECTION
1. CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK





a. Turn the crankshaft, and bring each piston to the Top Dead Center (TDC). Using a gasket scraper, remove all the carbon from the piston surface.





b. Using a gasket scraper, remove all the gasket material from the cylinder block surface.
c. Using compressed air, blow carbon and oil from the bolt holes.

CAUTION: Protect your eyes when using high-pressure compressed air.

NOTICE: Be careful not to scratch the cylinder head contact surface.

2. INSPECT CYLINDER BLOCK FOR FLATNESS
3. CLEAN CYLINDER HEAD





a. Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.

NOTICE: Be careful not to scratch the cylinder block contact surface.





b. Using a wire brush, remove all the carbon from the combustion chambers.

NOTICE: Be careful not to scratch the cylinder block contact surface.





c. Using a soft brush and solvent, thoroughly clean the cylinder head.





d. Using a valve guide bushing brush and solvent, clean all the guide bushings.
4. INSPECT CYLINDER HEAD





a. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder block and the manifolds for warpage.





Maximum warpage

If the warpage is greater than the maximum, replace the cylinder head.





b. Inspect for cracks.
Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.





5. CLEAN VALVES
a. Using a gasket scraper, chip off any carbon from the valve head.
b. Using a wire brush, thoroughly clean the valve.
6. INSPECT VALVE STEMS AND GUIDE BUSHINGS





a. Using a caliper gauge, measure the inside diameter of the guide bushing.
Bushing inside diameter: 5.510 - 5.530 mm (0.21693 - 0.21772 inch)





b. Using a micrometer, measure the diameter of the valve stem.





Valve stem diameter

c. Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement.





Standard oil clearance





Maximum oil clearance

If the clearance is greater than the maximum, replace the valve and cylinder head.
7. INSPECT VALVES





a. Check the valve is ground to the correct valve face angle.
Valve face angle: 44.5°
b. Check that the surface of the valve for wear.
If the valve face is worn, replace the valve.





c. Check the valve head margin thickness.





Margin thickness

If the margin thickness is less than minimum, replace the valve.





d. Check the valve overall length of the valve.





Overall length

If the overall length is less than minimum, replace the valve.
e. Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
8. INSPECT AND CLEAN VALVE SEATS





a. Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.





b. Check the valve seating position.
Apply a light coat of Prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve.
c. Check the valve face and seat for the following:
- If blue appears 360° around the face, the valve is concentric. If not, replace the valve.
- If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat.
- Check that the seat contact is in the middle of the valve face with the following width: 1.0 - 1.4 mm (0.039 - 0.055 inch)
If not, correct the valve seats as follows:





1) If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.





2) If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat.





d. Hand-lap the valve and valve seat with an abrasive compound.
e. After hand-lapping, clean the valve and valve seat.
9. INSPECT VALVE SPRINGS





a. Using a steel square, measure the deviation of the valve spring.
Maximum deviation: 1.6 mm (0.063 inch)
Maximum angle (reference): 2°
If the deviation is greater than the maximum, replace the valve spring.





b. Using vernier calipers, measure the free length of the valve spring.
Free length: 46.7 mm (1.799 inch)
If the free length is not as specified, replace the valve spring.





c. Using a spring tester, measure the valve spring tension.





Standard

If the tension is not as specified, replace the valve spring.