- Clamp the cylinder head in a vice by the bar attached to one of the exhaust manifold studs.
- To remove and install the valves, you need a special tool 09202-70010. The tool is installed on the cylinder head, as shown in Fig. 41. Tighten the tool, compressing the spring, and then remove the valve crackers. To remove the valves, you can also use a piece of pipe that fits onto the upper spring cup. On the other side, the spring cup should be well supported. Hit the pipe with a hammer so that the valve crackers can jump out. They fall into the pipe. The pipe should be pressed against the spring cup all the time so that the crackers do not fly apart.
Fig. 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 discard them immediately as they must be replaced. Assemble all the parts of each valve together. Place the valves on the bottom of an inverted cardboard box and write the valve number in front of each valve.
Fig. 42. Crushing of valve stem oil deflector caps from guide bushings (shown for engine 4A-F/FE).
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- Remove the valve tappets and adjusting washers from the holes and number them according to the cylinder numbers and valve assignment.
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, this is the exhaust camshaft. The work is performed 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 figures.
- On the 1.6L engine, insert the two bolts (1) and (2) into the corresponding holes of the secondary gear as shown in Fig. 43. Insert a screwdriver as shown in the figure and turn the secondary gear to the left so that the inserted bolt (3) can be pulled out. Do not damage the camshaft.
Fig. 43. Removing the tension of the camshaft drive gear spring on the 4AF/FE engine. The decoding of the part numbers is given in the text.
- On the 2.0L engine, insert bolt (2) into the secondary gear hole as shown in Fig. 44. Insert a screwdriver and turn the secondary gear so that bolt (1) can be removed from both halves of the camshaft gear.
Fig. 44. Relieving the tension of the camshaft drive gear spring on the 3S-FE engine. The decoding of the part numbers is given in the text.
- Using special pliers, remove the gear retaining ring and, in sequence, the corrugated washer (1), the secondary gear wheel (2) and the spring washer (3), see Fig. 45. Check all parts to see if they can be reinstalled.
Fig. 45. Details of the secondary gear of the camshaft of the intake or exhaust valves of the engines. The same parts are used on both engines. 1. Corrugated washer; 2. Secondary gear; 3. Spring washer