Engine Unit Replacement

Pry up the claws of the ventilation baffle plate.

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

Using a screwdriver, pry out the oil seal.

HINT:

Tape the screwdriver tip before use.

Place the oil seal retainer on wooden blocks.

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

HINT:

Tap the screwdriver tip before use.

Using SST and press, press out the bush.

SST

09222-30010

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

Place the cylinder head on wooden blocks.

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

SST

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

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

Place the cylinder head on wooden blocks.

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

SST

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

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).

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

Place the cylinder head on wooden blocks.

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.)

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.)

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).

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

Place the cylinder head on wooden blocks.

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.)

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.)

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

Using SST and a press, press in the bush.

SST

09222-30010

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

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.
   

Place the oil seal retainer on wooden blocks.

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.
   

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.
   

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.
   

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