- Clamp the cylinder head in a vice using a bar attached to one of the exhaust manifold studs.
- To remove and install the valves, a special tool 09202-70010 is required. The tool is installed on the cylinder head as shown in Fig. 41. Tighten the tool by compressing the spring, and then remove the valve cotters. To remove the valves, you can also use a piece of pipe that fits onto the upper spring cup. On the other hand, the spring cup should be well supported. Hit the tube with a hammer so that the valve crackers can pop out. They fall into the tube. The tube should be pressed against the spring cup all the time so that the crackers do not fly apart.
Pic. 41. Removing valves using a tool
- Remove the spring cups and springs. Remove the rings from the valve stems as shown in Fig. 42 and throw them away immediately as they need to be replaced. Assemble all parts of each valve together. Place the valves on the bottom of an upside-down cardboard box and write its number in front of each valve.
Pic. 42. Crushing the valve stem oil seals from the guide bushings (shown for engine 4A-F/FE).
- Remove the valve tappets and shims from the holes and number them according to the cylinder numbers and valve accessories.
These engines require disassembly of one of the camshafts. On the 4A-F/FE engine this is the intake camshaft, and on the 3S-FE engine it is the exhaust camshaft. The work is carried out as follows, but taking into account the differences between both engines:
- Clamp the camshaft square in a vice so that the camshaft is in the position shown in the corresponding figs.
- On a 1.6 liter engine, insert two bolts (1) And (2) into the corresponding holes of the secondary gear, as shown in Fig. 43. Indicated in Fig. insert the screwdriver and turn the secondary gear to the left so that the inserted bolt can be pulled out (3). Do not damage the camshaft.
Pic. 43. Relieving the spring tension of the camshaft drive gear on the 4AF/FE engine. The explanation of the part numbers is given in the text.
- On a 2.0 liter engine, insert the bolt (2) into the hole of the secondary gear, as shown in Fig. 44. Insert a screwdriver and turn the secondary gear so that the bolt can be removed (1) from both halves of the camshaft gear.
Pic. 44. Relieving the spring tension of the camshaft drive gear on the 3S-FE engine. The explanation of the part numbers is given in the text.
- Using special pliers, remove the gear retaining ring and, in sequence, the corrugated washer (1), secondary gear (2) and spring washer (3), see fig. 45. Check all the parts to see if they can be installed again.
Pic. 45. Details of the secondary gear of the camshaft of the intake or exhaust valves of engines. Both engines use the same parts. 1. Corrugated washer; 2. Secondary gear; 3. Spring washer