Engine Unit

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

REPLACEMENT

1. REMOVE TIMING CHAIN COVER OIL SEAL
(a) Using a screwdriver with its tip taped, pry out the oil seal.

HINT: Tape the screwdriver tip before use.

2. INSTALL TIMING CHAIN COVER OIL SEAL
(a) Place the timing chain cover on wooden blocks.
(b) Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
SST 09223-50010

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

3. REMOVE ENGINE REAR OIL SEAL
(a) Place the oil seal retainer on wooden blocks.
(b) Using a screwdriver with its tip taped and a hammer, tap out the oil seal.

HINT: Tape the screwdriver tip before use.

4. INSTALL ENGINE REAR 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, 09950-70010 (09951-07150)

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

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 09201-01055, 09950-70010 (09951-07100)

6. 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)
(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 0/5 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.

(d) Place the cylinder head on wooden blocks.
(e) Using SST, tap in a new valve guide bush to the specified protrusion height.
SST 09201-01055, 09950-70010 (09951-07100)
Protrusion height (A): 9.8 to 10.2 mm (0.3858 to 0.4016 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)

7. 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 09201-01055, 09950-70010 (09951-07100)

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)
(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.

(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. REMOVE CONNECTING ROD SMALL END BUSH
(a) Using SST and a press, press out the bush.
SST 09222-30010

10. 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 (see step 26.) 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.