Disassembly and Assembly

DISASSEMBLY
1. Follow the procedure outlined in the illustration, noting the following:





2. Using cylinder head bolt socket tool No. MB991654, or equivalent, loosen the cylinder head bolts and remove the cylinder head bolts.
3. Loosen bolts evenly little by little, taking several steps.

NOTE: Store removed valves, springs and other parts, tagged to indicate their cylinder No. and location for reassembly.





4. Remove valve, springs and other parts using valve spring compressor tool No. MD998772, or equivalent.





5. Use pliers to remove the valve stem seal.

CAUTION: Do not reuse the stem seals.

ASSEMBLY
1. Follow disassembly procedure in reverse order, noting the following:
2. Install the valve spring seat.





3. Using the valve seal installation tool No. MD998737, or equivalent, install a new stem seal to the valve guide.

NOTE: Improper installation can be a cause of leakage of oil down into the cylinder. Do not reuse the valve stem seal.








4. Install the valve spring so that its end with identification color is positioned on the rocker arm end.
5. Do not compress the valve spring excessively, or the bottom end of the retainer will damage the stem seal.





6. Ensue the proper cylinder head gasket is installed. The identification mark is 4G63K.





NOTE: When installing the cylinder head bolts, the length below the head of the bolts should be within (A): 99.4 mm (3.91 inch). If it is outside the limits, replace the bolts.

7. Apply engine oil to the bolt thread and the washer.





8. Tighten the bolts by the following procedure.
a. Tighten to 78 Nm (58 ft. lbs). In the order shown in the illustration.
b. Fully loosen in the reverse order of that shown.
c. Tighten bolts to 20 Nm (14.5 ft. lbs.) in the order shown.
d. Make a paint mark across each bolt head and cylinder head. Give a 90° turn to the bolts in the specified tightening sequence.
e. Give another 90° turn to the bolts and make sure that the paint mark on the head of each bolt and that on the cylinder head are on the same straight line.

CAUTION:
1. Always make a tightening angle just 90°. If it is less than 90°, the head bolt will be loosened.
2. If it is more than 90°, remove the head bolt and repeat the procedure.