ENGINE UNIT > REPLACEMENT

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1. REMOVE TIMING CHAIN COVER OIL SEAL


    A097898E01

  1. Using a screwdriver with its tip taped, pry out the oil seal.



2. INSTALL TIMING CHAIN COVER OIL SEAL


    A097921E02

  1. Place the timing chain cover on wooden blocks.

  1. Using SST, tap in the oil seal until its surface is flush with the timing gear case edge.

    SST
    09223-50010  

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

  1. Apply a light coat of MP grease to a new oil seal lip.



3. REMOVE ENGINE REAR OIL SEAL


    A097904E01

  1. Place the oil seal retainer on wooden blocks.

  1. Using a screwdriver with its tip taped and a hammer, tap out the oil seal.



4. INSTALL ENGINE REAR OIL SEAL


    G039580E01

  1. Place the oil seal retainer on wooden blocks.

  1. Using SST, tap in the oil seal until its surface is flush with the oil seal retainer edge.

    SST
    09223-15030  
    09950-70010   (09951-07150)

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



5. REMOVE INTAKE VALVE GUIDE BUSH


    A087006E03

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



    A097936E01

  1. Place the cylinder head on wooden blocks.

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

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



6. INSTALL INTAKE VALVE GUIDE BUSH


    A087011E01

  1. 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.)

  1. Select a new guide bush (STD or O/S 0.05).
    Bush Bore Diameter
    		Bush Size
    10.285 to 10.306 mm (0.4049 to 0.4057 in.)
    		Use STD
    10.335 to 10.356 mm (0.4069 to 0.4077 in.)
    		Use O/S 0.05
    If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush.
    If the bush bore diameter of cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.



    A087006E03

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



    A097938E01

  1. Place the cylinder head on wooden blocks.

  1. Using SST, tap in a new valve guide bush to the specified protrusion height.

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

    Protrusion height:
    9.8 to 10.2 mm (0.3858 to 0.4016 in.)

  1. 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.)



7. REMOVE EXHAUST VALVE GUIDE BUSH


    A097937E01

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

  1. Place the cylinder head on wooden blocks.

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

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



8. INSTALL EXHAUST VALVE GUIDE BUSH


    A087009E01

  1. 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.)

  1. Select a new guide bush (STD or O/S 0.05).
    Bush Bore Diameter
    		Bush Size
    10.285 to 10.306 mm (0.4049 to 0.4057 in.)
    		Use STD
    10.335 to 10.356 mm (0.4069 to 0.4077 in.)
    		Use O/S 0.05
    If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush.
    If the bush bore diameter of cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.



    A087006E04

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



    A097939E01

  1. Place the cylinder head on the wooden blocks.

  1. Using SST, tap in a new valve guide bush to the specified protrusion height.

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

    Protrusion height:
    7.6 to 8.0 mm (0.2992 to 0.3150 in.)

  1. Using a sharp 5.5 mm reamer, ream the valve guide bush to obtain the standard specified clearance.

    Standard oil clearance:
    0.030 to 0.065 mm (0.0012 to 0.0026 in.)



9. REMOVE CONNECTING ROD SMALL END BUSH


    A054717E04

  1. Using SST and a press, press out the bush.

    SST
    09222-30010  



10. INSTALL CONNECTING ROD SMALL END BUSH


    A054732E03

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



    A054717E05

  1. Using SST and a press, press in the bush.

    SST
    09222-30010  



    A054733E01

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

  1. 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.