1. |
Using remove the cylinder head bolts in the
order shown in the illustration.

|
2. |
Using the special tool (09222-28000,
09222-28100), remove the valve spring retainer lock. Next remove the
spring retainer, valve spring, spring seat and valve.
Arrange these parts so that they can be
reinstalled in their original positions.

| |
3. |
Remove the valve stem seals with
pilers.
Do not reuse the valve stem
seals. | |
1. |
Check the cylinder head for crack, damage and
coolant leakage. If cracked replace the cylinder
head. |
2. |
Remove scale, sealing compound and carbon
deposits completely. After cleaning the oil passages, apply
compressed air to verify that the passenges are not
clogged.

|
3. |
Check the cylinder head surface for flatness
in the direction as shown in the illustration. If flatness exceeda
the service limit in any direction, either replace the cylinder head
or machine the cylinder head matching surface lightly.
Flatness of
cylinder head gasket surface
Standard : Less than 0.03mm
(0.012in.)
Limit : 0.06mm
(0.0024in.)
| |
VALVES
1. |
Using a wire brush, clean the valve
thorughly.

|
2. |
Check each valve for wear, damage and
distortion of the head and the stem. Replace if necessary. If stem
end, hollowed out or worn, resurface as necessary. This correction
must be limited to a minimum. Also resurface the valve
face.
Replace the valve if the margin has decreased
to less than the service limit.
Margin
[Standard]
Intake : 1.15mm (0.0453in.)
Exhaust : 1.35mm
(0.0531in.)
[Limit]
Intake : 0.8mm (0.0315in.)
Exhaust : 1.0mm
(0.040in.)
| |
Valve spring
1. |
Check the free height of each valve spring. If
they exceed the service limit, replace the
springs. |
2. |
Using a square, test the squareness of each
spring. If a spring is excessively out-of-wquare, replace
it.
Valve
spring
[Standard]
Free height : 48.86mm
(1.9236in.)
Load : 18.3kg/39mm
(40.0kg/30.5mm)
Out-of-square : 1.5° or
less
[Limit]
Free height : -1.0mm
(-0.0394in.)
Out-of-square : 3°
|


|
Valve guide
Valve stem-to-guide
clearance
[Standard]
Intake : 0.02 ~ 0.05mm (0.0008 ~
0.0020in.)
Exhaust : 0.035 ~ 0.065mm (0.0014 ~
0.0026in.)
[Limit]
Intake : 0.1mm (0.0040in.)
Exhaaust : 0.13mm
(0.0051in.)
|


Replacing the valve seat ring
1. |
Cut away the inner face of the valve seat to
reduce the wall thickness.

|
2. |
Enlarge the diameter of the valve seat so that
it matches the specified oversize hole diameter of the new valve
seat ring. |
3. |
Heat the cylinder head to about 250°C (480°F)
and press-fit an oversize seat ring for the bore in the cylinder
head. |
4. |
Using lapping compound, lap the valve to the
new seat.
Valve seat
contact width
Intake : 1.1 ~ 1.5mm (0.0433 ~
0.0590in.)
Exhaust : 1.3 ~ 1.7mm (0.0512 ~
0.0670in.)
|
Valve seat insert oversizes
Description
|
Size mm
(in.)
|
Size mark
|
Seat ring height H
mm(in.)
|
Oversize hole
diameter I.D. mm(in.)
|
Intake valve Seat
ring
|
0.3
(0.012) O.S.
|
30
|
7.5 ~
7.7 (0.296 ~ 0.303)
|
33.300
~ 33.325 (1.3110 ~
1.3120)
|
0.6
(0.024) O.S.
|
60
|
7.8 ~
8.0 (0.307 ~ 0.315)
|
33.600
~ 33..625 (1.1339 ~
1.1347)
|
Exhaust valve Seat
ring
|
0.3
(0.012) O.S.
|
30
|
7.9 ~
8.1 (0.311 ~ 0.319)
|
28.800
~ 28.821 (1.1339 ~
1.1347)
|
0.6
(0.024) O.S.
|
60
|
8.2 ~
8.4 (0.323 ~ 0.331)
|
29.100
~ 29.121 (1.1457
1.1465)
|
|
Replacing valve guide
1. |
Using the special tool (09221-3F100 A/B), with
draw the old valve guide toward the bottom of cylinder
head. |
2. |
Recondition the valve guide hole so that it
can match the newly press-fitted oversize valve guide.

|
3. |
Using the special tool (09221-3F100 A/B),
press-fit the valve guide. The valve guide must be press-fitted from
the upper side of the cylinder head. Keep in mind that the intake
and exhaust valve guides are different in length.

Do not install a valve guide unless it
is oversize.

| |
4. |
After the valve guide is press-fitted, insert
a new valve and check for proper stem-to-guide
clearance. |
5. |
After the valve guide is replaced, check that
the valve is seated properly. Recondition the valve seats as
necessary.
Valve guide oversizes
Over size mm
(in.)
|
Size mark
|
Over size
valve Guide hole size mm (in.)
|
0.05
(0.002)
|
5
|
11.05
~ 11.068 (0.4350 ~
0.4357)
|
0.25
(0.010)
|
25
|
11.25
~ 11.268 (0.4429 ~
0.4436)
|
0.50
(0.020)
|
50
|
11.50
~ 11.518 (0.4528 ~
0.4535)
|
|
1. |
Clean each part before
assembly. |
2. |
Apply engine oil to the sliding and
rotating
parts. | |
1. |
Install the spring seats.
Using a special tool (09222-22001), tap the
seal in position lightly.
•
|
Do not reuse old valve stem
seals. |
•
|
Incorred installation of the seal
could resuit in oil leakage past the valve
guides. | | |
2. |
Apply engine oil to each valve. Insert the
valve into the valve guide. Avoid pushing the valve into the seal by
force. After inserting the valve, check that it moves
smoothly.

|
3. |
Place valve springs so that the side coated
with enamel faces toward the valve spring retainer and then install
the retainer.

|
4. |
Using the special tool (09222-28000,
09222-28100), compress the spring and install the retainer locks.
After install the valves, ensure that the retainer locks are
correctly in place before releasing the valve spring
compressor.

When the spring is compressed, check
that the valve stem seal is not pressed against the bottom of
the
retainer. | |
5. |
Clean both gasket surfaces of the cylinder
block and cylinder head. |
6. |
Verify the identification marks on the
cylinder head gasket. |
7. |
Install the gasket so that the surface with
the identification mark faces toward the cylinder
head. |
8. |
Tighten the bolts to the specified torque in
the sequence shown below.

Cylinder head
bolt
M10 : 25Nm (250kg.cm, 18lb.ft) +
(60°~65°) + (60°~65°)
M12 : 30Nm (300kg.cm, 22lb.ft) +
(60°~65°) + (60°~65°)
| | |