Necessary equipment
09916-14510 Valve spring compressor
EN-48247 Valve Spring Compression Pressure Adapter
EN-48252 Camshaft oil seal installer
Disassembly procedure
1. Remove the cylinder head. follow the paragraph «Cylinder head and gasket» in this section.
2. Remove the intake manifold. See paragraph «Intake manifold» in this section.
3. Remove the exhaust manifold. follow the paragraph «An exhaust manifold» in this section.
4. Remove the vacuum pump. See Part 1F1, Engine Controls - 2.0 Diesel.
5. Remove the camshaft sprocket.
6. Remove the camshaft cover.
7. Remove the camshaft.
8. Remove the intake/exhaust roller pins
9. Remove the intake/exhaust valve bridge.
10. Remove the intake/exhaust valve clearance compensator.
11. Install valve spring compressor 09916-14510 (a) together with EN-48247 valve spring compression pressure adapter (b) on the cylinder head.
12. To compress the valve spring, turn the valve spring compressor knob 09916-14510.
13. Remove the valve key.
14. Remove the valve spring retainer.
15. Remove the valve spring.
16. Remove valves.
17. Remove the valve stem seal.
Checking the cylinder head
1. Clean sealing surfaces.
2. Check the cylinder head for the following conditions.
- Cracks, damage or chipping of the surface in the combustion chambers;
- Foreign particles in the lubrication channels; Thoroughly clean the channels from foreign particles;
- Coolant leaks or damage to the sealing surface of the front side of the cylinder head;
- Damage to any gasket surfaces;
- Damage to the threaded holes of any of the bolts;
- Burnt or eroded zones in the combustion chamber;
- Cracks in the exhaust channels and in the combustion chambers;
- External cracks in water channels;
- Restrictions in inlet or outlet channels;
- Restrictions in the channels of the cooling system;
- Rusty, damaged or leaking plugs.
3. If cracks or damage are found on the cylinder head, it must be replaced. It is not recommended to carry out welding work on the cylinder head or repair damage.
4. Measure the clearance between the ruler and the face of the cylinder head at four points along the ruler using a gap gauge.
5. Check the sealing surfaces for deformation and distortion. The sealing surfaces of the cylinder head must be aligned to within 0.05 mm (0.002 inch).
6. Measure the height of the cylinder head from the sealing surface to the sealing surface. Cylinder head height must be between 129.9 and 130.1 mm (5.1142 to 5.1220 inches). If the height of the cylinder head is less than the specification, replace the cylinder head.
Checking valves
1. Check for damage to the valve from the head to the stop as follows.
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2. Is there surface chipping in the valve seat area? (1)
3. Is the valve edge correct? (2)
4. Is there a kink in the valve stem (3)
5. Is there surface chipping or excessive wear in the stem (4)
6. Are the valve key grooves worn? (5)
7. Is the valve stop worn? (6)
8. Replace valve if any of these symptoms appear.
9. Check valve springs. If the end of the valve spring is not parallel, replace the valve spring.
10. Check the valve swivel seat for wear or chips. Replace if necessary.
Cleaning procedure
1. Clean the cylinder head.
2. Clean the valve guides.
3. Clean all threaded holes.
4. Clean the valves from soot, oil and carbon deposits.
Assembly procedure
1. Lubricate the valve stems with engine oil.
2. Carefully return the valves to their original position.
3. Install the valve stem seal.
4. Install the valve spring.
5. Install the valve spring seat.
6. Install the valve.
7. Install the valve spring retainer.
8. Compress the valve springs with valve spring compressor 09916-14510 (a) and valve spring compression pressure adapter EN-48247 (b).
9. Install the valve key.
10. Remove valve spring compressor tool 09916-14510 (a) and valve spring compression pressure adapter EN-48247 (b).
11. Install valve clearance adjusters.
12. Install valve bridges.
13. Install the valve rocker pins.
14. Apply sealant (LOCTITE 573) on the sealing surface of the front/rear camshaft cover.
15. Install the camshaft.
16. Install the camshaft cover.
Tighten
Tighten the camshaft cover bolts to 28 Nm (20.7 lb-ft).
17. Install the front camshaft seal using the EN-48252 camshaft oil seal installer (a).
Note: If damaged, the front camshaft oil seal must be replaced with a new one. When installing the front camshaft oil seal on the oil pump, make sure that the oil seal groove faces in the direction of the contact on the oil pump housing.
18. Install the camshaft sprocket.
Tighten
Tighten the camshaft sprocket bolt to 133 Nm (98.1 lb-ft).