Service Learning Objectives ‘After studying this chapter, you will be able to: + Explain how to inspect and service the camshaft. * Summarize service procedures for in-block and overhead valve assemblies. * Describe the steps in inspecting and reconditioning valve seats. * Explain how to inspect and recondition valve lifters and valve guides. Introduction The valve train performs several vital functions. Itallows air-fuel mixture to enter the cylinder during the intake stroke, seals the combustion chamber cur ing the compression and power strokes, and allows hot combustion gases to escape during the exhaust stroke, In order for the engine to function efficiently, each part in the valve train must be in good condi- tion and functioning property. If any one part in the system is worn or damaged, it will quickly wear related components, resulting in rapid engine failure. For this reason, every part must be carefully inspected and measured for wear. If a worn or damaged part is found, it should be reconditioned or replaced. All other parts in physical contact with the worn part will also likely need to be recondi- tioned or replaced. Camshaft Service Begin valve train service by inspecting the cam- shaft for wear or damage, especially on the bearing, Camshaft and Valve Train poppet valves valve seat width surfaces, cam lobes, and timing gear. Look for chips, nicks, and worn edges on the timing gear teeth. If any damage is found, the camshaft timing gear must be replaced. Any other gears in contact with the damaged gear, such as the crankshaft timing gear, oil slinger gears, or governor gears, must be closely reinspected. Any gear in contact with a worn cam- shaft gear likely has matching wear. If a new cam- shaft or timing gear is installed without replacing the other worn gears it is in contact with, the new gear will quickly wear out. ing gears on many crankshafts and camshafts serviceable. In these cases, the entire aft or crankshaft must be replaced ifthe timing damaged. Next, use an outside micrometer to measure the camshaft journal surfaces for wear, Com- pare the camshaft journal diameter to the reject size specified by the manufacturer. Use an inside micrometer, telescoping gauge, or small hole gauge to measure bearing bores in the crankcase cover 341a Section 4 Engine Service and crankcase, Figure 18-1. If either of the diam- eters is greater than the manufacturer's reject size, a new bushing must be installed, or the crankcase or cover replaced Next, use a micrometer to measure the dis- tance from the bottom of the cam lobes to the top. See Figure 18-2. Compare these values to the manufacturer's reject sizes. If either measure- ment is smaller than the reject sizes specified, replace the camshaft. Bearing clearance can be determined by subtracting the camshaft bear ing journal measurement from camshaft bearing, bore measurement. Measure the camshaft lobe length from the bottom of the cam lobe to the top. Many small engines are equipped with centrifu- gally operated compression release systems. These typically consist of a weighted, spring-loaded lever that moves a pin in the cam lobe. When the engine is stationary, the pin holds the exhaust valve open. As the camshaft rotates more quickly, the weighted lever overcomes spring pressure and moves outward, When the lever moves outward, the pin in the cam Jobe drops, allowing the exhaust valve to close fully If the camshaft is equipped with one of these systems, ensure that the weighted lever can move freely. Make sure that the spring action returns the lever to proper position, and that the pin moves freely. See Figure 18-3. If there is a problem with Check the camshaft bearing journals and bores for wear. A—Measure the camshaft bearing journals with an outside micrometer. B—Measure the camshaft bores in the crankcase and crankcase cover with a Make sure that the compression release system telescoping gauge or small hole gauge. operates properly.Chapter 18 Camshaft and Valve Train Service the compression release system, sometime a thor- ough cleaning will fix it. IF not, replace the com- pression release mechanism. Valve Service Four-cycle engines contain poppet valves, which are subjected to tremendous heat. The nor- mal operating temperature of the exhaust valve exceeds 1000°F. To withstand this heat, high-qual- ity, heat-resistant steel must be used and the cor- rect operating clearances must be maintained. Inspecting Valves and Seats When the valves have been removed, clean them with a power-operated wire brush and inspect them for the following defects: + Eroded, cracked, or pitted valve faces, heads, or stems. + Warped valve head. See Figure 18-4. * Worn or improperly ground valve stems. See Figure 18-4. * Bent valve stems. + Margin less than 1/64”, + Partial seating Heavy carbon deposits on intake valves some- times cause faulty valve operation by restricting the flow of fuel into the cylinder. If any serious defects are observed, the valve should be replaced. If a valve is to going to be reused, the valve face should be machined to a smooth, true finish. Warped Head Thin Margin Worn or improperly ground valve stems ~ Sy ‘A warped valve head, thin margin, or worn stem indicates the need for valve reconditioning or replacement. Inspecting Valve Springs Through overheating and extensive use, valve springs can lose their elasticity and become dis- torted (warped or bent). Check each spring for squareness and proper length with a square and a surface plate. See Figure 18-5. Replace all springs that are badly distorted or reduced in length. Valve Guides Valve guides align the valves with the valve seats so that they can open fully and close com- pletely. Guide-to-valve stem clearance must not exceed tolerances, since this would permit the valve to tip. Tipping causes the valve face to strike the seat at an improper angle, resulting in a gap that allows hot combustion gases to escape. Some clearance is required, however, to allow for heat expansion and lubrication. Generally, guide-to-valve stem clear- ance should run about 002” to 008" Gree Use a square and a surface plate to check a valve spring for proper length and squareness.344 Valve guides can bea replaceable insert or an inte- gral part of the block, See Figure 18-6, Most replace- able guides are cast iron, Worn replaceable guides can be replaced by driving the old guide out and driving, in a replacement guide. Worn integral guides can be reconditioned by reaming the guide oversize so itcan be fitted with a new valve with an oversize stem, Inspecting Valve Guides Valve guides must be cleaned before inspec- tion. A special cylindrical wire brush, driven by a power drill, is made for this job. After cleaning the guide, measure the bore with a small hole gauge. See Figure 18-7, Expand the gauge until it lightly touches the sides of the bore. Remove the gauge and measure it with a micrometer. Next, measure the valve stem diameter with a micrometer. See Figure 18-8. Subtract the stem diameter from the guide diameter to find the Section 4 Engine Service Valve seat Integral valve guide A B Gro Replaceable valve guide ‘There are two types of valve guides. A—Integral valve Quides are part of the block. 8—Guides that are pressed into the block can be replaced, GUE Valve guides must be measured for wear. A—Valve guide diameter can be measured with a small hole gauge. B—The small hole gauge measurement is transferred to a micrometer.Chapter 18 Camshaft and Valve Train Service Measure the valve stem clametr ard subact the ve glide dameter to detormine he velve serio gude clearance. precise amount of clearance. If the value exceeds the clearance specified by the manufacturer, the guide must be serviced to restore proper clearance. Some manufacturers have special plug, gauges for checking guide clearance. If this special tool can be inserted into the valve guide a specified distance, the valve guide is worn and should be replaced. Correcting Worn Integral Aluminum Guides If the clearance between the valve stem and an integral aluminum valve guide exceeds the allowable limit, two different methods can be used to correct the clearance, depending on the engine make and model. If valves with oversize stems are available for the engine, enlarge the guide to the next oversize dimen- sion with an adjustable reamer. Next select and install a replacement valve with the correct oversize stem. If valves are not available for the engine being overhauled, thin-walled valve guide bushings may be available. In such cases, the following pro- cedure should be used to correct valve clearance, using either procedure to correct valve clearance, not enlarge the lifter guides. Lifters with oversized 1. Measure the guide clearance with a small hole gauge or plug gauge, Figure 18-94. 2. Ifthe clearance exceeds manufacturer specifications, lubricate the counterbore reamer with cutting oil and place it into the valve guide, Push the pilot bushing over the counterbore reamer until the bushing is in solid contact with the valve seat. 3. Set the replacement bushing on the pilot bushing, Mark the reamer 1/16” above the top of the replacement bushing. See Figure 18-9B. 4, Turn the reamer clockwise slowly and smoothly to ream the valve guide. During the reaming operation, periodically lubricate the guide with cutting oil. Stop when the mark on counterbore reamer is even with the top of the pilot bushing, See Figure 18-9C. 5. When the guide is reamed to size, pull the reamer back out of the guide, while continuing to turn it clockwise. Mark Mark Plug gauge] Pilot bushing Replacemeit bushing Pilot of —~ (counterbore reamer Finish reamer — Bushing driver —>]]_ < oe elt Replacement Replacement bushing bushing — D E Figure 1 Replacing worn aluminum valve guides with new valve guide bushings. (Briggs & Stratton Corp.)6. Place the replacement bushing in the valve guide and press it in with a bushing driver. The bushing should be driven until itis flush with the top of the valve guide. See Figure 18-9D. 7. Use a proper-size finishing reamer to finish ream the bushing all the way through. Apply smooth pressure while turning the reamer handle clockwise to ream the bushi Periodically lubricate the bushing with cutting oil during the process. See Figure 18-9E. 8, Spray penetrating oil into the top of the guide to wash away all metal filings before removing the reamer. Pull the reamer out of the guide while turning it clockwii pedure shown in Figure 18-9 is one example of thod used for several engine models. The engine serviced may require slighty cifferent techniques. ys follow the manufacturer's service procedure. Valve Guide Bushing Replacement Some engines have valve guides that are replace- able by driving out the worn guide bushings and pressing in new bushings. For each make and model, the manufacturer's service manuals should be exam- ined to determine the proper method, bushings, and tools to use. Typically, iron guides are driven out through the bottom of their bores. Guides made of brass or other soft metals are typically pulled out through the top of their bores. Replacing Worn Brass or Sintered lron Guides Replaceable valve guides that require replace- ment are typically driven out through the bottom of their bores with a bushing driver if they are iron. If they are brass or other soft metal, driving the bush- ing out could fracture the guide and cause damage to the bore. These types of guide bushings are typically tapped and pulled out through the top of their bores. See Figure 18-10. The depth of the bushing must be ‘measured before the worn bushing is removed. The replacement guide bushing is then driven or pressed into the bore to the same depth as the old bushing. Refacing Valves Valve refacing can be done on a specially designed grinder. The valve is revolved while being fed over an abrasive wheel. The collet that holds the valve Section 4 Engine Service —— Puller screw _—— Puller nut Threaded valve guide io Often, a soft metal guide is removed by tapping threads inthe bushing, which is then extracted out of the top ofits bore with a puller setup like the one shown here. (Briggs & Stratton Corp) is adjusted to achieve the desired face angle. Cool- ant flows over the valve head during grinding to reduce heat and produce a good surface finish. The feed wheel is used to precisely control the amount of material being ground from the valve face. In some cases, a specially designed lathe called a valve cutter can be used to reface valves. See Figure 18-11 Valve refacing can also be done using a manual valve refacer. See Figure 18-12. The valve is placed tightly intoa machinist’s vise. Then, the valve refacer is placed on the valve. The crank lever turns the 45° (or 30°) cone against the stationary valve face. The cone has carbide blades that cut the valve face to the desired angle. The crank lever provides enough leverage to make the job effortless. The second lever is used to control the feed rate of the blades. Valve Lifter Service Inspect valve lifters to ensure that the cam lobe contact area is not excessively worn. See Figure 18-13. If the cam lobe contact surfaces are concave or deformed in any other way, the surfaces must be ground flat on a grinding wheel or the lift- ers replaced. If a lifter appears to be in good shape, install it into its guide and check for excessive play. The lifter should move up and down in its guide without resistance and without excessive side play. Refer to the manufacturer's service manual for theChapter 18 Camshaft and Valve Train Service ‘The handle of the manual valve refacer is turned by hand Until the desired face angle is achioved. (Neway Mfg. Co.) Valve cutters can be used to reface valves. A—A valve cutter is a lathe specially designed to cut and true the valve face with a carbide cutting tool. B—Closeup of a valve face being turned and trued on a valve cutter. (Neway Mfg. Co.) Inspect the vaive lifters. A~—Chack the cam lobe contact, surfaces for wear. 8—Put the lifer in its bore and make sure it moves freely, without excessive side play.corrective steps to take if the lifter hangs up in its, bore or has excessive side play. Valve Seat Service Valve seats should always be reconditioned or replaced during an engine overhaul. Begin by inspecting the valve seat to make sure it is not loose or damaged. If a replaceable valve seat insert is burned, pitted, or otherwise damaged, it should be replaced. If an integral valve seat is damaged, in some cases it may be possible to bore out the old seat and install a valve seat insert. In other cases, the most economical solution is to replace the block. Ifthe valve seat is in good condition, the only service that may be required is a light cutting to remove small surface imperfections. Peening a Valve Seat Insert Peening refers to displacing metal just outside the edge of the valve seat insert to lock the insert in place. If a valve seat insert is loose, it may be pos- sible to secure the insert by peening it. However, be aware that a loose valve seat insert may have damage that makes it unsuitable for reuse. Always make sure the old valve seat insert is in good con- dition before securing it, To secure a loose valve seat, place the insert squarely in its bore. Then, use a center punch and ‘hammer to tap the insert at three equidistant points around its rim. This ensures the insert is fully seated. Next, use a small flat-ended drift punch or pin punch to make small indentations in the block ‘metal just outside of the insert’s rim. Work around the insert in a star pattern, pening points directly across from each other to ensure the insert does become tilted in its bore as it is secured, The small indentations created by pening flatten the metal, forcing it outward so it overlaps the top of the insert, locking the insert in place. Italso bulges the block metal under the punch outward, forcing it into contact with the side of the insert. See Figure 18-14, Valve Seat Angle and Width Anytime an engine is overhauled, the valve seats should be cut to ensure that they are smooth and have the proper angle and width. The correct valve seat angle is necessary for proper valve seat- ing, Valve seats are generally cut to a 45° angle, although 30° seat angles are used in a few engines. Follow all of the manufacturer’s recommendations. Section 4 Engine Service 1. Loose valve seat can be turned or moved up or down. Check with {eeler gauge 3. Use a flat punch to een over edge around entire insert 2. Use center punch to tighton insert at three points equally spaced «@ we | Steps for securing a valve seat insert. 1—If the space between the insert and cylinder is more than .005", a new insert must be installed. 2—A center punch is used in three equally spaced locations to hold the insert for the peening operation. 3—A flat end punch about 1/8” diameter is used to force metal against the insert to hold ittightly in place. (Briggs & Stratton Corp.) squeezed against insert The valve seat width is important for effective valve system operation. The seat must be wide enough to prevent cutting into the valve face. It must also pro- vide enough contact area for adequate heat dissipa- tion. On the other hand, the seat must not be too wide. Ifitis, carbon will pack between the seat and the valve face, holding the valve off the seat. A valve that fails to seat results in a rough-running engine and will quickly warp and bum. Seat widths typically range from 030" to 060" (1/32” to 1/16"), See Figure 18-15. .030"-.060" lax Valve seat Valve seat ‘A ype integral va seats shown hor. The hol for the boats bagea e onk met Note the ples valve seat angle and valve seat widths.Chapter 18 Camshatt and Valve Train Service Some valve seats are finished to an angle 1° greater or less than the valve face. The 1° varia- tion produces a hairline contact that results in fast initial seating. Some manufacturers believe that, upon heating, the valve will form a perfect seal. The difference in the angle between the valve face and the valve seat is called an interference angle. See Figure 18-16. Valve seat contact must be near the center of the valve face. See Figure 18-17. Refacing (Cutting) Valve Seats Valve seats should be cut with a special valve seat cutting tool that has sharp carbide blades, such as the one shown in Figure 18-18. These tools can be purchased separately or in a kit like the one in Figure 18-19. If the carbide cutter blades become dull, they can be easily replaced. The cutting blades have angular teeth to give a smooth shearing cut as they are turned. See Figure 18-20. Valve face Figure 18: ‘A1° difference between the valve face and the valve seat provides better seating. Correct Incorrect Comparison of correct and incorrect location of the Seating aon ona vale ace (Deore 88) Pilot igure 18-18, A valve seat cutting tool with carbide cutting blades. This tool is used to recondition valve seats by hand. (Neway Mig. Co.) valve seat cutting toolkit. The cutter heads have carbide cutter biades that are very hard and will cut smooth and precise angles. Pilot rods accommodate various valve guide sizes. (Neway Mig. Co.)Figure 18-20, Valve cutter heads have angled cutting edges that provide a chatterless shearing cut for smooth vaive seat surfaces. (Neway Mig. Co.) ‘The amount of cutting required depends on valve seat condition. If the valve seat is in good con- dition and has the correct seat angle and width, a single turn of the cutter may be all that is required to remove any minor imperfections. If the valve inspection revealed evidence of improper valve seating or the valve seat angle or width is incor- rect, more seat material will need to be removed, Before cutting a valve seat, use a black felt tip marker to completely color the seat area. As the seat is cut, the black marker ink will be shaved away, revealing the clean metal underneath. This will make it easier to judge the progress of the cut. After marking the valve seat, place the pilot rod in the valve guide, and then slide the valve seat cut- ter over the pilot. The tee handle wrench is used to turn the cutter. Apply moderate downward pres- sure and turn the cutter clockwise only. Cutting action is controlled by steady pressure and smooth turning of the handle. After every one or two turns, remove the cut- ter and check the progress of the cut. Clean metal should be visible in the seat area. Any area still covered by black ink remains uncut, When the seat is cut to the proper width and has no irregu- larities, stop cutting, Figure 18-21 illustrates the correct procedure to follow when using a valve cutter and pilot. Follow the cutter manufacturer's instructions for correcting various problems with seat geometry. jing any cutting operation, such as ye guides or cutting valve seats, any chips thoroughly washed away, Section 4 Engine Service Replacing Valve Seat Inserts If valve seat inserts are damaged or worn, they can be removed and replaced with new inserts. The procedures described in this section are general in nature, and may not be suitable for all engines. Always follow the procedures in the manufacturer's service manual for the specific engine being serviced. ‘Typically, the old valve seat insert is removed using a puller like the one shown in Figure 18-22. The puller nut is positioned under the valve seat insert, Then, the slotted puller body is slid around the puller bolt and centered over the insert. The bolt is tightened to pull the insert from its bore. A slide hammer with a special adapter or a pry bar can also be used to remove most valve seat inserts. Care must be taken not to damage the insert bore. One outside edge of a replacement valve seat insert is chamfered. The insert should be set in the bore with the chamfered side down, Figure 18-23. Then, the old insert is turned upside down and set on top of the replacement insert. The pilot shaft of the valve seat insert driver is installed through the opening in the old insert, the opening in the new insert, and into the valve guide, See Figure 18-24. Next, make sure that the inserts are properly aligned over the bore, and drive the new insert until it bottoms in the bore. Finally, peen the metal around the insert to secure it and then reface the insert as described earlier. If the engine has integral valve seats, it may be possible to counterbore the valve seats 50 valve seat inserts can be installed. A special cutter is used to enlarge the valve seat bore to a specified depth. The insert is installed in the bore with the chamfered edge down. Then, the valve seat insert is driven into place and secured by peening the metal around the insert. See Figure 18-25, Reface the seat as previously described in this chapter. Lapping Valves Some engine manufacturers recommend hand lapping of the valve seats. Lapping compound is available from engine parts distributors. Lapping compound consists of silicon carbide abrasive com- bined with a special grease. It is generally available in course grade and fine grade. The course grade removes more metal than the fine grade. The con- dition of the valve will dictate which grade to use.Chapter 18 Camshaft and Valve Train Service Valve Seat Cutter Kit GENERAL INSTRUCTIONS SELECTION AND USE OF PROPER PILOT 2 SOLID PILOTS. Plot pul pin All blades are adjustable 1. Solect a pilot same diameter (Fractional or metric) AShoulder es he as valve guide. should 2. Insert pilot in valve guide twisting slighty unt jy not touch very snug, Pilot shoulder should not touch = nD Cl valve guide. (Fig. 1) + if small, try next size larger. Vave Sy + If too large, try next smaller size. guide Fig. 4 Hex key, DETAILED CUTTING INSTRUCTIONS Blade. Pointed Bottom Bottom end A. Slowly lower cutter to valve seat. D0 NOT DROP narrowing [il narrowin 4 CUTTER. cutter Flat need B. Tum clockwise and apply very light pressure. Release the down pressure at end of each cut Proper care of cutting blades Make one or two turns with no pressure. C. BOTTOM NARROWING CUT. 1. Cut lightly with narrowing cuter (usually 60°) 2, Cut unti a fine continuous line is formed with valve seat. (Fig. 2) D. TOP NARROWING CUT. Apply S} Patways tum} Serrations on the blades very ‘dlockwise | should be cleaned regularly 1. Cut lightly with narrowing cutter (usually 15"). light with the brush provided with For engines with hemispheric combustion pressure, each kit. (A toothbrush chambers, use 30'/31" could also be used.) 2. Cut until seat width is slightly less than required (This operation LOWERS THE SEAT) Lye | Proper care of cutters E. FINAL SEAT CUT. ro8 and pilots 4. Cut lightly, with seat cutter (usually 31° or 46°) Handle 2, Cut seat to proper width. This should take only Lue with with a few turns. (Fig. 3) pilot puller pin. | Cara F. INSPECT SEAT, 1. Remove pilot, using pilot puller. (Fig. 4) 2. Insert valve in valve guide. Pitot The tools should be kept in 3. Tap valve slighty up and down in the guide : tool case. When removed (holding it with tingors top and bottom—above Valve from case, they should be and below the cylinder nead). Do this unt seat guide placed on a cloth or pad. contact ring shows on the valve face. Fig. 4 ‘These precision instruments will last a long time if reasonable cara is used, Proper procedures for using a valve seat cutting tool. (Neway Mig. Co.)Section 4 Engine Service valve seat insert Figure 18-22. ‘A valve seat puller tool removes old valve seat inserts. A—The puller nut is inserted through the hole and held in place with a finger in the port, The puller body is placed on the bolt and over the insert. B—When the nut on the Puller is tightened with a wrench the insert is pulled up and out. (Briggs & Stratton Corp.) Valve seat insert oso ‘down Valve seat Figi rE ‘When installing the insert, the chamfered edge should be placed down in the bore, Driving the valve insert into place with a driver tool and ball peen hammer. A pilot guides the driver tool (Briggs & Stratton Corp.) ‘Aluminum: bee Pilot If the coarse lapping compound is used, follow. Valve guide up with the finer compound. Apply the lapping compound to the valve face only, Figure 18-26. Pes compere seul ote alo fa ociat the valve stem or guide. Next, a lapping tool is ‘The old insert is used to drive in the new insert and seat so that it wl be sightly bolow the surace. attached to the valve head by means of a suction (Briggs & Stratton Corp.) cup. See Figure 18-27. With the tool attached, theChapter 18 Camshaft and Valve Train Service ‘Apply lapping compound to the valve face before lapping the face to the seat To use a lapping stick, attach the stick to the valve head with a suction cup. valve is placed in the guide and twirled back and forth. See Figure 18-28, The lapping process is complete when a dark gray, narrow band, which is equal to the seat width, can be seen alll the way around the valve face. Do not lap more than is necessary to create a properly sized seat. ‘After lapping, thoroughly clean the valve and valve seat chamber so that none of the abrasive finds its way into the engine. The best way to clean the seat area is to turn the engine upside down and wash the chamber with solvent, from the bottom, Lap the valve to the seat by twirling the lapping stick between the palms of the hands. Lift the lapping stick and valve occasionally to increase the culting action of the compound. Many manufacturers no longer recommend lapping Valves. Check the manufacturer's service manual to determine if the lapping procedure is recommended for the engine being serviced. Adjusting Valve Lifter-to-Stem Clearance Valve clearance refers to the space between the end of the valve stem and the top of the valve lifter when the valve is closed, The amount of clearance needed depends on engine design and use. Due to hotter operation, the exhaust valve often requires more clearance than the intake valve. Clearances of around .008” for the intake valve and 012” for the exhaust valve are fairly common. Always refer to the manufacturer's specifications. ‘When there is too little valve clearance, the valve may be held open when the valve stem heats up and lengthens (expands). As a result, engine performance is poor and both the valve face and valve seat will bum. See Figure 18-29, Insufficient clearance can also alter valve timing, making it too far advanced.Burning gases 1 _stem Y] — O-fieekes ae VM A A =~ A B rae Valve clearance setting is essential to good engine performance. A—Correct clearance permits valve to seat, B—Lack of clearance keeps valve open. Too much valve clearance, on the other hand, will make valve timing late and reduce valve lift This results in sluggish engine performance. It can also cause rapid lifter wear because of the pound- ing action involved. Under these conditions, the engine will be noisy and the valve could break Figure 18-30 shows a complete small L-head engine valve train, After a valve has been refaced, it rides lower in the guide, and, therefore, the valve lifter-to- stem clearance is reduced. If the engine does not have adjustable lifters, the end of the valve stem must be ground to obtain correct clearance. To check clearance, turn the camshaft until the lobe is away from the lifter. Hold the valve against its seat while testing clearance with a thickness gauge, Figure 18-31. If there is too little clear- ance, remove the valve and grind .001” or .002" off the end of the stem. Repeat the clearance check and grinding operation until the clear- ance is correct, Soction 4 Engine Service Valve Guide Spring Valve stem-to-lter clearance CE Components of a complete L-head engine valve train, (Kohier Co.) ao Hold the valve against its seat and slide a feeler gauge blade between the valve stem and liter. The clearance is equal to the thickest blade that will fi Servicing Overhead Valves, Seats, and Guides The valves, seats, and guides used in overhead valve systems are serviced in the same way as those in L-head engines (also called flat head orChapter 18 Camshaft and Valve Train Service side valve engines). Valves should be cleaned and resurfaced to a 45° angle (or a 30° angle) on a valve grinding machine. Valve seats can be reconditioned with a valve seat cutting tool. Valves should be lapped if recom- mended by the manufacturer. Thoroughly clean lapping compound from valve seats and faces. Inspect and measure valve springs. Replace any parts that do not meet specifications. Measure the intake and exhaust valve guides If dimensions are not within specifications, the guides must be replaced. To remove worn guides, use a bushing driver or flat-ended pin punch. Sup- port the cylinder head and press the guides out. See Figure 18-32. When pressing new guides into Pressing a valve guide out of a cylinder head with a bushing driver or a flat punch. (Briggs & Stratton Corp.) a cylinder head, press only to the specified depth See Figure 18-33, This dimension will vary from one engine model to another. Drive the replacement valve quide to the specified height ‘above the hole, as shown. (Briggs & Stratton Corp.)Summary After valves are removed, clean and inspect them for defects. Valves with serious defects must be replaced. Valve springs should be checked for squareness, length, and tension. Replace all sptings that are not within specifications Check valve guides with a small hole gauge. If the clearance between the guide and stem ex- ceeds the allowable limit, enlarge the guide with an adjustable reamer. A new valve with an over- size stem must be installed. Valve seats are generally cut to a 45° angle. Seat contact must be near the center of the valve face. A valve seat cutter is used to recondition seats. Good used valves can be reseated by a hand-lapping process. Valve clearance refers to the space between the end of the valve stem and the top of the lifter: Valves must be closed when measuring clearance, If there is too little clearance, the valve may be held open when the stem expands. Valve refacing can be done on a specially de- signed grinder or with a manual valve refacer. Valve clearance is reduced when a valve is refaced. Therefore, the tappets must be adjusted or the valve stem end must be ground to obtain the cor- rect clearance, Review Questions Answer the following questions on a separate sheet of paper. 1. A camshaft timing gear is inspected and found to be severely worn. In addition to replacing the camshaft, what further actions should the technician take and why? 2. How is a centrifugally operated compression release checked? 3. Valve margins should not be less than AL 1/64 B. 1/32 c. 1/16 D. 3/32 4, After reaming a valve guide, bushing, or cutting a valve seat it is important to immediately 5. Why is it important to select the correct valve guide bushing before reaming the block? Section 4 Engine Service Select 6. Valve seats that are too wide will correct answer(s). ‘A. cause valves to stick closed B. cause valves to stick open C. transfer too much heat to the block D. warp and burn 7. What is the 1° difference between the valve face angle and the valve seat angle called? 8. How isa valve seat insert secured in the cylinder head bore? A. Itis tack welded in place. B. Itis held in place by peening metal surrounding the insert C. Itis held in place with a snap ring, D. Itis threaded into place. 9. Name the process of placing abrasive compound on the valve face and twirling the valve back and forth in the valve seat 10, Too little valve clearance will cause the valve to A. break B. be noisy c. burn D. open late Suggested Activities Grind valves on a grinding machine or turn and true valve faces on a valve cutter. 2. Recondition old valve seats with a valve seat cutter. 3. Lap valves into seats after the valve faces and seats are reconditioned by grinding. 4, Ream new valve guides in an aluminum, block engine having aluminum guides, 5. Remove old valve guide bushings and install new guide bushings. 6. Demonstrate removing an old valve seat insert. 7. Demonstrate counterboring a cylinder for a new valve seat insert. 8, Demonstrate pening a valve seat on an aluminum engine block. 9. Ream valve guides to fit oversize valve stems with proper clearance. 10. Adjust lifter-to-valve clearance by grinding valve stems.CHAPTER 18 Camshaft and Valve Train Service Name Date Class _ Learning Objectives After studying this chapter, you will be able to: * Explain how to inspect and service the camshaft. * Summarize service procedures for in-block and overhead valve assemblies. * Describe the steps in inspecting and reconditioning valve seats. * Explain how to inspect and recondition valve lifters and valve guides. Instructions: After studying the chapter, complete the following questions and problems, 1. List the three basic functions performed by the valve train. 2. Ifan inspection of the camshaft reveals chips, worn edges, or broken teeth on the timing gear, the timing gear or camshaft must be replaced. What additional action(s) should be taken? ‘Copyright by The Goodhoar Wieox Co, Ine Small Gas Engines Workbook 973. Identify the procedure shown in the following image. Describe the procedure for checking a centrifugally operated compression relief mechanism for proper operation, 5. Valve faces, heads, and stems should be inspected for erosion, cracking, and pitting, List four other conditions that valves should be inspected for. . Valve springs should be inspected for_and 7. True or False? Valve guides must be cleaned with a wire brush before they are measured for wear. 8. Proper valve guide-to-stem clearances are typically _. A. .020".030" B. .010"-020" CC. .005"-010" D. .002"-.003" If an integral aluminum valve guide is worn beyond 9 specification, A. the cylinder block must be replaced B._ the valve guide should be reamed and clearance restored by installing a valve with an oversize stem or a thin-walled bushing C. the valve guide and valve lifter guide should be reamed and clearance should be restored by installing valves and lifters with oversized stems D. None of the above. 98 Small Gas Engines Workbook Copyright by The Goocheart Nila: Co neChapter 18 Camshaft and Valve Train Service Name 10. Replaceable valve guides made of are typically 10. driven out through the bottom of their bore. 1. Replaceable valve guides made of metal are 11, threaded and pulled out through the top of their bores. 12. A specially designed lathe calleda(n)__canbeused 12. to teface valves. 13. True or False? Valve lifters should never be reused inan 13. engine rebuild. 14, True or False? Valve seats should always be reconditioned 14. or replaced during an engine overhaul. 15. What procedure is being shown in the following drawing? insert 16, Most valve seats are cut toanangleof___°or__° 16. 17. The difference in angle between the valve face and the 17. valve seat in certain engines is called a(n) 18. Which drawing in the following figure illustrates proper 18. valve seat contact? ‘Copyright by The Goodhesr-Wlleox Co, ne ‘Small Gas Engines Workbook 9919. Explain why some technicians color a valve seat with a black marker before cutting the seat. 20. True or False? Replacement valve seat inserts should be 20. inserted in the bore with the chamfered edge down. 21. Lapping compound isa combination of___and___. 21. 22. Lapping compound should be applied to the __of 22 the valve only. 23. Explain how to determine when the lapping process is complete. 2A. The best way to clean the seat areas following valve 24. lapping is the ‘A. wipe the valve seat clean with a lint-free towel B. wash the seat area with water and blow dry with compressed air C. turn the engine upside down and wash the valve seats with solvent D. None of the above. 25. Valve clearance refers to the space between the end of 25. the valve stem and the top of the __when the valve is closed, 26. What problem(s) can be caused by insufficient valve clearance? 27. What problem(s) can be caused by excessive valve clearance? 28. Valve clearance is measured with a(n) __. 28 A. feeler gauge B. dial indicator C. inside micrometer D. None of the above. 100 Small Gas Engines Workbook Copyright by The Goodrear Wilox Co, IneChapter 18 Camshaft and Valve Train Service Name Research and write complete answers to the following questions. 29. Describe the parts of overhead valve systems and how they work. 30. Explain how the camshaft lobe profile affects valve lift and duration, Copyighby Tho Gooshoar Wea Co, In ‘Small Gas Engines Workbook 101102 Small Gas Engines Workbook