Reassembly

CYLINDER HEAD ASSEMBLY:

Assembly

CAUTION: When installing rocker arms, camshaft and oil seal, lubricate contacting surfaces with new engine oil.
When tightening cylinder head bolts, camshaft sprocket bolts and camshaft bracket bolts, lubricate bolt threads and seat surfaces with new engine oil.






If a hydraulic lash adjuster is kept on its side, there is a risk of air entering it. When hydraulic lash adjusters are removed, stand them straight up or soak them in new engine oil.
Do not disassemble hydraulic lash adjusters.
Attach tags to lash adjusters so as not to mix them up.






1. Install valve component parts.
Install valves, noting their identification marks as indicated in the table.

Valve Identification Mark:

Always use new valve oil seal.
Before installing valve oil seal, install valve spring seat.






Install valve spring (uneven pitch type) with its narrow pitched side (paint mark) toward cylinder head side.
After installing valve components, use plastic hammer to lightly tap valve stem tip to assure a proper fit.

Fig. 35 Checking Hydraulic Lash Adjuster:

2. Check hydraulic lash adjusters.
a. Push on the rocker arm above the hydraulic lash adjuster. If it moves 1 mm (0.04 inch) or more, there is air in the high pressure chamber of hydraulic lash adjuster.

NOTE: Noise will be emitted from hydraulic lash adjuster if engine is started without bleeding air.






b. Remove hydraulic lash adjuster and dip in a container filled with new engine oil. While pushing plunger as shown in figure, lightly push check ball using a thin rod. Air is completely bled when plunger no longer moves.

NOTE: Air cannot be bled from this type of lash adjuster by running engine.






3. Remove camshafts, rocker arms and shims. For future reference, identify each shim with the cylinder it was removed from. Since the shims are reusable, it may not be necessary to replace all of the existing shims.






4. Before attempting any measurement, make sure the valve, valve spring, collet, retainer and rocker arm guide are properly installed in the head.

NOTE: Always replace rocker arm guide with a new one.

CAUTION: Install parts in their original positions.






5. Install the J38957-1 gauge plate into the tapped holes at the cam journals and secure it to the head using two of the hex bolts supplied with the kit. (The two remaining bolts are spares.)






6. Place the J38957-2 collar on the J38957-8 dial indicator. Make sure the dished side of the collar is facing "up" (toward the dial indicator). Secure the collar to the dial indicator by tightening the set screw in the collar.
7. Place the indicator and collar over #1 cylinder intake valve shim side. Slide the tip of the dial indicator through the access hole and place it on the end of the valve stem. While resting the dial indicator collar on the gauge plate, "zero" the dial indicator.






8. Move the dial indicator and collar to the adjacent hole in the gauge plate and place the tip of the indicator in the center of the rocker arm guide. Write down the dial indicator reading. This measured distance between the valve stem end and the contact surface of the rocker arm guide is the "T1" dimension.

9. Match the measured "T1" dimension (in inch) to the available shim chart (in millimeters). Refer to Engine; Specifications; Mechanical.
(The "T1" dimension is equivalent to the thickness and size designation of the valve shim.) Select the closest size shim to the measured "T1" dimension.
For example, if the measured "T1" dimension is 0.1152 inch, use a 2.925 mm (0.1152 inch) shim. Shims are available in 17 different thicknesses ranging from 2.800 mm (0.1102 inch) to 3.200 mm (0.1260 inch) and increase in increments of 0.025 mm (0.0010 inch).

10. Repeat this procedure on the remaining cylinders.






11. Install intake manifold with intake manifold collector as shown.






12. Install exhaust manifold.
Tighten exhaust manifold bolts in numerical order.

Exhaust manifold: .........37.8 - 48.1 Nm (3.8 - 4.9 kg-m, 28 - 35 ft. lbs.)






13. Install EGR volume control valve assembly.





14. Install EGR tube.
15. Install exhaust manifold cover.
16. Install water outlet.
a. Remove old liquid gasket from mating surface of water outlet.
Also remove old liquid gasket from mating surface of cylinder head.






b. Apply a continuous bead of liquid gasket to mating surface of water outlet.

NOTE: Use Genuine RTV silicone sealant part No. 999MP-A7007 or equivalent.