Part 2

OVERHAUL (CONTINUED)

23. INSPECT EXHAUST VALVE
a. Using vernier calipers, measure the valve's overall length.
Standard overall length: 106.74 mm (4.2024 inch)
Minimum overall length: 106.44 mm (4.1905 inch)
If the overall length is less than the minimum, replace the valve.

b. Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter: 5.465 to 5.480 mm (0.2151 to 0.2157 inch)

c. Using vernier calipers, measure the valve head margin thickness.
Standard margin thickness: 1.2 to 1.6 mm (0.0472 to 0.0630 inch)
Minimum margin thickness: 0.50 mm (0.0197 inch)
If the margin thickness is less than the minimum, replace the valve.

24. INSPECT VALVE GUIDE BUSHING
a. Using a caliper gauge, measure the inside diameter of the guide bush.
Bush inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 inch)
b. Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.
Standard oil clearance:
0.025 to 0.060 mm (0.0010 to 0.0024 inch) (Intake)
0.030 to 0.065 mm (0.0012 to 0.0026 inch) (Exhaust)
Maximum oil clearance:
0.08 mm (0.0032 inch) (Intake)
0.10 mm (0.0039 inch) (Exhaust)

HINT:
- If the clearance is greater than the maximum, replace the intake valve and intake guide bush (see steps 25 and 27).
- If the clearance is greater than the maximum, replace the exhaust valve and exhaust guide bush (see steps 26 and 28).

25. 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)

26. 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)

27. 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 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 09201-01055, 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)

28. 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)

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

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)

29. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN

NOTICE: It is not necessary to remove w/ head pin unless it is being replaced.

a. Using a plastic-faced hammer, tap in a new ring pin until the pin stops.

30. INSTALL TIGHT PLUG NO.1

NOTICE: If water leaks from the tight plug or the plug corrodes, replace it.

a. Apply adhesive to the tight plug hole of the cylinder head.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent.

b. Using SST, tap in a new tight plug to the cylinder head as shown in the illustration.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)

31. INSTALL STUD BOLT

NOTICE: If the stud bolt is deformed or the threads are damaged, replace it.

a. Using E6 and E7 torx socket wrenches, install the stud bolts.
Torque:
3.0 Nm (31 kgf-cm, 27 inch lbs.) for stud bolt A
7.5 Nm (76 kgf-cm, 66 inch lbs.) for stud bolt B
9.5 Nm (97 kgf-cm, 84 inch lbs.) for stud bolt C

32. INSTALL W/HEAD STRAIGHT SCREW PLUG NO.1
a. Using a 10 mm hexagon wrench, install 3 new gaskets and the straight screw plugs.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)

33. INSTALL W/HEAD STRAIGHT SCREW PLUG NO.2
a. Using a 19 mm hexagon wrench, install a new gasket and the straight screw plug.
Torque: 90 Nm (918 kgf-cm, 66 ft. lbs.)

34. INSTALL OIL CONTROL VALVE FILTER
a. Check that no foreign matter is on the mesh part of the filter.
If foreign objects are present, clean the part thoroughly.
b. Using a 8 mm hexagon wrench, install a new gasket and the oil control valve filter with the screw plug.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
35. INSTALL VALVE SPRING SEAT
a. Install the valve spring seats to the cylinder head.

36. INSTALL VALVE STEM OIL SEAL
a. Apply a light coat of engine oil to new oil seals.

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

HINT: The intake valve oil seals are white and the exhaust valve oil seals are black.

b. Using SST, push in the oil seals.
SST 09201-41020

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

37. INSTALL INTAKE VALVE
a. Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.

b. Install the valve, compression spring and spring retainer to the cylinder head.

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

c. Using SST and wooden blocks, compress the spring and install the 2 retainer locks.
SST 09202-70020 (09202-00010)

d. Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

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

38. INSTALL EXHAUST VALVE
a. Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.

b. Install the valve, compression spring and spring retainer to the cylinder head.

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

c. Using SST and wooden blocks, compress the spring and install the 2 retainer locks.
SST 09202-70020 (09202-00010)

d. Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

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

39. INSTALL VALVE LASH ADJUSTER ASSEMBLY

NOTICE:
- Keep the lash adjuster free from dirt and foreign objects.
- Only use clean engine oil.

a. Place the lash adjuster into a container full of engine oil.
b. Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the checkball inside the plunger.
SST 09276-75010
c. Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
d. Check the movement of the plunger and bleed the air. OK: Plunger moves up and down.

NOTICE: When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the checkball as shown in the illustration. If the checkball is not pressed, air will not bleed.

e. After bleeding the air, remove the SST. Then quickly and firmly press the plunger with a finger.
OK: Plunger is very difficult to move.
If the result is not as specified, replace the lash adjuster.

f. Install the lash adjusters.

NOTICE: Install the lash adjuster to the original position.

40. INSTALL VALVE STEM CAP
a. Apply a light coat of engine oil to the valve stem caps.
b. Install the valve stem caps to the cylinder head.