Disassembly and Assembly
DISASSEMBLY1. Remove rocker arms, shims, rocker arm guides and hydraulic lash adjusters. Keep disassembled parts in order.
2. Remove throttle chamber with Accel-drum unit.
3. Remove EGR tube and exhaust manifold cover.
4. Remove exhaust manifold, then fuel tube assembly.
5. Remove intake manifold.
6. Remove intake manifold collector from intake manifold.
7. Remove water outlet and electrical connector.
8. Remove thermostat housing with water pipe.
9. Using valve spring compressor, remove valve components and oil seal.
ASSEMBLY
1. Install water electrical connector.
2. Install thermostat housing with water pipe.
3. Install water outlet.
4. Install intake manifold collector to intake manifold.
5. Install intake manifold and fuel tube assembly.
6. Install exhaust manifold and cover.
7. Install EGR tube.
8. Install throttle chamber with Accel-drum, then adjust Accel-drum.
9. Install valves component parts, noting the following:
a. Install valves, ensuring intake is 53J and exhaust 64Y.
b. Always use new gasket valve oil seals.
c. Before installing valve oil seal, install inner valve spring seat.
d. Install outer valve spring with its narrow pitch side toward cylinder head side.
e. Tap valve stem lightly with plastic mallet after installing to ensure proper fit.
10. Check hydraulic lash adjusters as follows:
a. When rocker arm can be moved 0.04 inch by pushing at hydraulic lash adjuster location, it indicates there is air in high pressure chamber.
b. Noise will be emitted from hydraulic lash adjuster if engine is started without bleeding air.
Fig. 36 Bleeding Hydraulic Lash Adjuster:
c. Remove hydraulic lash adjuster and dip in a container filled with clean engine oil. While pushing plunger as shown in Fig. 11, lightly push check ball using a thin rod. Air is completely bled when plunger no longer moves. Air cannot be bled from this type of lash adjuster by running engine.
11. Install rocker arm, shims, rocker arm guides and hydraulic lash adjuster.
12. Select a suitable shim when replacing valve, cylinder head, shim, rocker arm guide and/or valve seat with new one(s) as follows:
a. Install valve components parts to cylinder head (except shim), then replace rocker guide.
b. Remove hydraulic lash adjuster.
Fig. 12 Hydraulic lash adjuster installation:
c. Install dial gauge stand tool No. J38957, or equivalent, into hydraulic lash adjuster fixing hole, Fig. 12.
Fig. 29 Pulling Dial Indicator Tool:
Fig. 14 Rocker arm guide shim selection measurement:
d. Measure difference T(1) between sliding surface of rocker arm guide against rocker arm and valve stem end on shim side with valve, valve spring, collet, retainer and rocker arm guide installed to head (except shim). When measuring, lightly pull dial indicator rod toward you to eliminate play in measuring tool No. J38957, or equivalent, Figs. 13 and 14.
e. Select a shim having thickness of measurement T(1) plus or minus 0.0010 inch. Shims are available in different thickness ranging from 0.1102 to 0.1260 inch in increments of 0.0010 inch.