Reassembly

CYLINDER HEAD

COMPONENTS:

REASSEMBLY

REPLACEMENT
1. REMOVE INTAKE VALVE GUIDE BUSH

a. Gradually heat the cylinder head to approximately 80 to 100°C (176 to 212°F).

b. Using SST and a hammer, tap out the guide bush.
SST 09201-10000, 09950-70010 (09951-07100)
2. INSTALL INTAKE VALVE GUIDE BUSH

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

b. Select a new guide bush (STD or O/S 0.05).

Standard Bush Bore Diameter:

HINT:
^ If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 inch), machine the bush bore diameter to between 10.335 and 10.356 mm (0.4068 to 0.4077 inch).
^ If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 inch), replace the cylinder head.

HINT: Different bushes are used for the intake and exhaust.

Standard intake bush length: 34.5 mm (1.358 inch)
c. Gradually heat the cylinder head to approximately 80 to 1 00°C (176 to 212°F).

d. Using SST and a hammer, tap in a new guide bush to the specified protrusion height.
SST 09201-10000, 09950-70010 (09951-07100)
Standard protrusion height (H): 9.2 to 9.8 mm (0.362 to 0.386 inch)

e. Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem.
3. REMOVE EXHAUST VALVE GUIDE BUSH

a. Gradually heat the cylinder head to approximately 80 to 100°C (176 to 212°F).

b. Using SST and a hammer, tap out the guide bush.
SST 09201-10000, 09950-70010 (09951-07100)
4. INSTALL EXHAUST VALVE GUIDE BUSH

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

b. Select a new guide bush (STD or O/S 0.05).

Standard Bush Bore Diameter:

HINT:
^ If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 inch), machine the bush bore diameter to between 10.335 and 10.356 mm (0.4068 to 0.4077 inch).
^ If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 inch), replace the cylinder head.

HINT: Different bushes are used for the intake and exhaust.

Standard exhaust bush length: 40.5 mm (1.594 inch)
c. Gradually heat the cylinder head to approximately 80 to 100°C (176 to 212°F).

d. Using SST and a hammer, tap in a new guide bush to the specified protrusion height.
SST 09201-01055, 09950-70010 (09951-07100)
Standard protrusion height (H): 8.2 to 8.8 mm (0.323 to 0.346 inch)

e. Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem.

REASSEMBLY

1. INSTALL CAMSHAFT SUB GEAR
a. Install the gear spring (1), sub-gear (2) and wave washer (3).

HINT:
Attach the pins on the gears to the gear bolt washer ends.

b. Using snap ring pliers, install the snap ring.

c. Mount the hexagon head portion of the camshaft in a vise.

NOTICE:
Be careful not to damage the camshaft.

Recommended Service Bolt:

d. Using SST, align the holes of the driven main gear and sub-gear by turning the-sub gear clockwise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
e. Align the gear teeth of the driven main gear and sub-gear, and tighten the service bolt.

2. INSTALL CAMSHAFT TIMING TUBE ASSEMBLY
a. Insert a new oil seal into the camshaft timing tube until it reaches the stopper.

NOTICE:
^ Be careful of the installation direction.
^ Do not turn over the lip of the oil seal.

b. Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.
c. Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several passes.
SST 09960-10010 (09962-01000, 09963-00500)
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

NOTICE:
Be careful not to damage the timing tube.

d. Mount the hexagon head portion of the camshaft in a vise.

NOTICE:
Be careful not to damage the camshaft.

e. Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom.
f. Using a 10 mm hexagon wrench, install the bolt.
Torque: 78 Nm (795 kgf-cm, 58 ft. lbs.)
g. Install the seal washer and screw plug.
Torque: 15 Nm (152 kgf-cm, 11 ft. lbs.)

3. INSTALL SPARK PLUG TUBE

HINT:
When using a new cylinder head, the spark plug tubes must be installed.

a. Apply adhesive to the end of the spark plug tube.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent.

NOTICE:
^ Install the spark plug tube within 3 minutes after applying adhesive.
^ Be careful not to deform the spark plug tube.
^ Be careful not to expose the seal to coolant for at least 1 hour after installing it.

b. Using a wooden block and hammer, tap in a new spark tube until there is 40.9 to 42.1 mm (1.610 to 1.658 inch) protruding from the camshaft bearing cap installation surface of the cylinder head.

NOTICE:
To avoid tapping in a new spark plug tube too far, measure the protrusion length while tapping it.

4. INSTALL TIGHT PLUG
a. Apply adhesive to the end of the spark plug tube.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent.
b. Using SST and a hammer, tap in a new tight plug as shown in the illustration.
SST 09550-60010 (09951-00300), 09950-70010 (09951-07100)

5. INSTALL RING PIN

6. INSTALL STUD BOLT

7. INSTALL VALVE STEM OIL SEAL
a. Using SST, push in a new oil seal.
SST 09201-41020

NOTICE:
Failure to use SST will cause the seal to be damaged or improperly seated.

b. Apply a light coat of engine oil in a new oil seal.

NOTICE:
Pay close attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust or installing the exhaust oil seal to the intake can cause installation problems later.

HINT:
The intake valve oil seal is gray/brown and the exhaust valve oil seal is black/gray.

8. INSTALL INTAKE VALVE
a. Install the valve, spring seat, valve spring and spring retainer.
b. Using SST, compress the valve spring and place the 2 spring retainer locks around the valve stem.
SST 09202-70020 (09202-00010)

9. INSTALL EXHAUST VALVE
a. Install the valve, spring seat, valve spring and spring retainer.

NOTICE:
Install the same parts in the same combination to their original locations.

b. Using SST, compress the valve spring and place the 2 spring retainer locks around the valve stem.
SST 09202-70020 (09202-00010)

c. Using a plastic-faced hammer and a discarded valve with its tip wrapped in vinyl tape, lightly tap the installed valve to ensure that it is securely fit.

NOTICE:
Be careful not to damage the valve stem tip.

10. INSTALL VALVE LIFTER
a. Install the valve lifter and shim.
b. Check that the valve lifter rotates smoothly by hand.