1. |
Drain the coolant and disconnect the upper
radiator hose. |
2. |
Remove the breather hose and air-intake
hose. |
3. |
Remove the vacuum hose, fuel hose and coolant
hose. |
4. |
Remove the intake
manifold. |
5. |
Remove the cables from the spark plugs. The
cables should be removed by holding the boot
portion. |
6. |
Remove the ignition
coil. |
7. |
Remove the upper and lower timing belt
cover. |
8. |
Remove the timing belt and camshaft
sprockets. |
9. |
Remove the heat protector and exhaust manifold
assembly. |
10. |
Remove the coolant pump pulley and head
cover. |
11. |
Remove the intake and exhaust
camshaft.


|
12. |
Remove the cylinder head assembly. The
cylinder head bolts should be removed using the S12 mm socket, in
two or three steps. |
13. |
Clean the gasket pieces from the cylinder
block top surface and cylinder head bottom surface.
Make sure that fragments from the gasket
do not fall in the engine.

| |
1. |
Remove scale, sealing compound and carbon
deposits. After cleaning oil passages, apply compressed air to make
certain that the passages are
notclogged. |
2. |
Visually check the cylinder head for cracks,
damage or water leakage. |
3. |
Check the cylinder head surface for flatness
with a straight edge and feeler gauge as shown in the
illustration.
Cylinder head
flatness
Standard dimensions : Max. 0.03mm
(0.0059 in.)
Service limit : 0.05mm (0.0020
in.)
| |

Valve Guides
Valve stem-to-guide
clearance
Standard value
Intake : 0.02 ~ 0.05mm (0.0009 ~
0.0020in.)
Exhaust : 0.035 ~ 0.065mm (0.0014 ~ 0.0026
in.)
Service limit
Intake : 0.10mm(0.0039 in.)
Exhaust : 0.15mm(0.0059
in.)
|


Valve
1. |
Replace the valve if its stem is bent, worn or
damaged. Also replace it if the stem end (the surface contacting the
hydraulic-lash adjuster) ishollowed
out. |
2. |
Check the valve face contact area, and
recondition or replace as
necessary. |
3. |
Replace the valve if the width of the margin
(thickness of the valve head) is less than the minimum
specified.
Valve
margin
Standard value
Intake : 1.0mm(0.0394 in.)
Exhaust : 1.3mm(0.0512 in.)
Service limit
Intake : 0.5mm (0.0197in.)
Exhaust : 0.8mm
(0.0315in.)
|

|
Valve Spring
1. |
Check the free height of each valve spring and
replace if necessary. |
2. |
Using a square, test the squareness of each
valve spring. If the spring is excessively out-of-square, replace
it.
Valve
spring
Standard value
Free height : 42.5mm (1.6732
in.)
Load : 21.9kg/35mm (48.4
lb/1.3780in.)
Out of squareness : Max.
1.5°
Service limit
Load : 21.9kg/34mm (48.4
lb/1.3386in.)
Out of squareness : Max.
3°
|

|
Replacing Valve Guide
1. |
Using the special tool (09221-3F100 A/B),
withdraw the old valve guide out the bottom of the cylinder
head. |
2. |
Recondition the valve guide hole so that it
can receive the newly press-fitted oversize valve
guide.
Valve Guide Oversizes
Size mm
(in.)
|
Size mark
|
Oversize valve guide hole
size mm(in.)
|
0.05
(0.002) O.S.
|
5
|
11.050
~ 11.068 (0.435 ~
0.4357)
|
0.25
(0.010) O.S.
|
25
|
11.250
~ 11.268 (0.443 ~
0.4436)
|
0.50
(0.020) O.S.
|
50
|
11.500
~ 11.518 (0.453 ~
0.4535)
|

|
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 guidesare different in
length. |
4. |
After the valve guide is press-fitted, insert
a new valve and check for proper
clearance. |
5. |
After the valve guide is replaced, check that
the valve is fully seated. Recondition the valve seats as
necessary.
Do not install a valve guide unless it
is oversize.

| |
Replacing 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 hole diameter of the new valve seat
ring.

Valve Seat Ring 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
|
7.9 ~
8.1 (0.311 ~ 0.319)
|
33.300
~ 33.325 (1.311 ~
1.312)
|
Exhaust valve Seat
ring
|
0.3
(0.012) O.S.
|
30
|
7.9 ~
8.1 (0.311 ~ 0.319)
|
28.600
~ 28.625 (1.126 ~
1.127)
|
|
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 (0.043 ~
0.059in.)
Exhaust : 1.3 ~ 1.7mm(0.051 ~ 0.067
in.)
| |
1. |
Install the spring
seats. |
2. |
Using special tool (09222-22001), lightly tap
the seal in position.
•
|
Do not reuse old valve stem
seals. |
•
|
Incorrect installation of the seal
could result in oil leakage of from the valve
guides.

| | |
3. |
Apply engine oil to each valve. Insert the
valve into their guides. Avoid pushing the valve into the seal by
force. After installing the valve,check that it moves
smoothly. |
4. |
Place valve springs so that the side coated
with enamel faces toward the valve spring retainer.

|
5. |
Using the special tool (09222-28000,
09222-28100), compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer locks are
correctly in place before releasing the valvespring
compressor.
When the spring is compressed, check
that the valve stem seal is not pressed against the bottom of
the retainer.

| |
6. |
Clean both gasket surfaces of the cylinder
head and cylinder block. |
7. |
Verify the identification marks on the
cylinder head gasket. |
8. |
Install the gasket so that the surface with
the identification mark faces toward the cylinder head.
Do not apply sealant to these
surfaces.

| |
9. |
Tighten the cylinder head bolts in the
sequence shown in the illustration with a torque
wrench.

|
10. |
Tighten the cylinder head bolts using the
torque-angle method. Starting at top center, tighten all cylinder
head bolts in sequence as shown in the illustration, using the 12 mm
socket.
Tightening
procedure
Cylinder head bolt :
25Nm (250kg.cm, 18.1lb.ft) + (58°~62°) +
(43°~47°)
|


|