Engine Unit, Replacement

ENGINE UNIT

REPLACEMENT





1. REMOVE SPARK PLUG TUBE GASKET
a. Pry up the claws of the ventilation baffle plate.
b. 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
a. Using a screwdriver, pry out the oil seal.

HINT: Tape the screwdriver tip before use.





3. REMOVE REAR ENGINE OIL SEAL
a. Place the oil seal retainer on wooden blocks.
b. 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
a. Using SST and press, press out the bush.
SST 09222-30010

5. REMOVE INTAKE VALVE GUIDE BUSH
a. Heat the cylinder head to 80 to 100°C (176 to 212°F).
b. Place the cylinder head on wooden blocks.





c. 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
a. Heat the cylinder head to 80 to 100°C (176 to 212°F).
b. Place the cylinder head on wooden blocks.





c. 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
a. 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 inch)





b. Select a new guide bush (STD or O/S 0.05).
If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 inch), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 inch) 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 inch), replace the cylinder head.
c. Heat the cylinder head to 80 to 100°C (176 to 212°F).
d. Place the cylinder head on wooden blocks.





e. 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 inch)





f. 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 inch)





8. INSTALL EXHAUST VALVE GUIDE BUSH
a. 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 inch)





b. Select a new guide bush (STD or O/S 0.05).
If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 inch), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 inch) 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 inch), replace the cylinder head.
c. Heat the cylinder head to 80 to 100°C (176 to 212°F).
d. Place the cylinder head on wooden blocks.





e. 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 inch)





f. Using a sharp 5.5 mm reamer, ream the valve guide bushing to obtain the standard specified clearance.
Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 inch)





9. INSTALL CONNECTING ROD SMALL END BUSH
a. Align the oil holes of a new bush and the connecting rod.





b. Using SST and a press, press in the bush.
SST 09222-30010





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





d. 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
a. Place the oil seal retainer on wooden blocks.
b. Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.
SST 09223-15030

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





11. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
a. 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: Keep the lip free from foreign matter. Do not tap on the oil seal at an angle. Make sure that the oil seal edge does not stick out of the timing chain case.





12. INSTALL SPARK PLUG TUBE GASKET
a. Using a 32 mm socket wrench, tap in 6 new spark plug tube gaskets to the head covers.

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

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