ENGINE UNIT > REPLACEMENT

for Preparation Click here



1. REMOVE SPARK PLUG TUBE GASKET


A106241

  1. Pry up the claws of the ventilation baffle plate.

  1. Using a screwdriver with its tip taped and hammer, tap out the 3 gaskets.



2. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL


A108818

  1. Using a screwdriver, pry out the oil seal.

    HINT:
    Tape the screwdriver tip before use.



3. REMOVE REAR ENGINE OIL SEAL


A076248E01

  1. Place the oil seal retainer on wooden blocks.

  1. Using a screwdriver and a hammer, tap out the oil seal.

    HINT:
    Tap the screwdriver tip before use.



4. REMOVE CONNECTING ROD SMALL END BUSH


A054717E01

  1. Using SST and press, press out the bush.

    SST
    09222-30010  



5. REMOVE INTAKE VALVE GUIDE BUSH

  1. Heat the cylinder head to 80 to 100°C (176 to 212°F).

  1. Place the cylinder head on wooden blocks.



    A106193E02

  1. Using SST and a hammer, tap out the guide bush.

    SST
    09201-10000   (09201-01050)
    09950-70010   (09951-07100)



6. REMOVE EXHAUST VALVE GUIDE BUSH

  1. Heat the cylinder head to 80 to 100°C (176 to 212°F).

  1. Place the cylinder head on wooden blocks.



    A106194E02

  1. Using SST and a hammer, tap out the guide bush.

    SST
    09201-10000   (09201-01050)
    09950-70010   (09951-07100)



7. INSTALL INTAKE VALVE GUIDE BUSH


A109626

  1. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

    Cylinder bore diameter:
    10.285 to 10.306 mm (0.4049 to 0.4057 in.)

    Select a new guide bush (STD or O/S 0.05):
    Bush size
    		Bush bore diameter
    Use STD
    		10.285 to 10.306 mm (0.4049 to 0.4057 in.)
    Use O/S 0.05
    		10.335 to 10.356 mm (0.4069 to 0.4077 in.)

    If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush.
    If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

  1. Heat the cylinder head to 80 to 100°C (176 to 212°F)

  1. Place the cylinder head on wooden blocks.



    A107839E02

  1. Using SST, tap in a new valve guide bush to the specified protrusion height.

    SST
    09201-10000   (09201-01050)
    09950-70010   (09951-07100)

    Protrusion height:
    10.20 to 10.60 mm (0.4016 to 0.4173 in.)



    A109627

  1. Using a sharp 5.5 mm reamer, ream the valve guide bush to obtain the standard specified clearance.

    Standard oil clearance:
    0.025 to 0.060 mm (0.0010 to 0.0023 in.)



8. INSTALL EXHAUST VALVE GUIDE BUSH


A109628

  1. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

    Cylinder bore diameter:
    10.285 to 10.306 mm (0.4049 to 0.4057 in.)

    Select a new guide bush (STD or O/S 0.05):
    Bush size
    		Bush bore diameter
    Use STD
    		10.285 to 10.306 mm (0.4049 to 0.4057 in.)
    Use O/S 0.05
    		10.335 to 10.356 mm (0.4069 to 0.4077 in.)

    If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush.
    If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

  1. Heat the cylinder head to 80 to 100°C (176 to 212°F).

  1. Place the cylinder head on wooden blocks.



    A107840E01

  1. Using SST, tap in a new valve guide bush to the specified protrusion height.

    SST
    09201-10000   (09201-01050)
    09950-70010   (09951-07100)

    Protrusion height:
    9.30 to 9.70 mm (0.3661 to 0.3819 in.)



    A109629

  1. Using a sharp 5.5 mm reamer, ream the valve guide bushing to obtain the specified clearance.

    Standard oil clearance:
    0.030 to 0.065 mm (0.0012 to 0.0026 in.)



9. INSTALL CONNECTING ROD SMALL END BUSH


A054732E01

  1. Align the oil holes of a new bush and the connecting rod.



    A054717E01

  1. Using SST and a press, press in the bush.

    SST
    09222-30010  



    A109624

  1. Using a pin hole grinder, hone the bush to obtain the specified clearance between the bush and piston pin.



    A109625

  1. Check that the piston pin fits at normal room temperature.

    1. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.



10. INSTALL REAR ENGINE OIL SEAL


A106113E01

  1. Place the oil seal retainer on wooden blocks.

  1. Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.

    SST
    09223-15030  

    NOTICE:
    1. Keep the lip free from foreign matter.
    2. Do not tap on the oil seal at an angle.



11. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL


A106152E02

  1. Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.

    SST
    09316-60011   (09316-00011)

    NOTICE:
    1. Keep the lip free from foreign matter.
    2. Do not tap on the oil seal at an angle.
    3. Make sure that the oil seal edge does not stick out of the timing chain case.



12. INSTALL SPARK PLUG TUBE GASKET


A095166E01

  1. Using a 32 mm socket wrench, tap in 6 new spark plug tube gaskets to the head covers.

    NOTICE:
    1. Keep the lip free foreign matter.
    2. Do not tap on the oil seal at an angle.

  1. Return the claw of the ventilation baffle plate to its original position.