REMOVAL AND INSTALLATION

Removal steps <<A>> >>F<< 1. Cylinder head bolt >>F<< 2. Cylinder head bolt washer 3. Cylinder head assembly >>E<< 4. Cylinder head gasket <<B>> >>D<< 5. Valve spring retainer lock 6. Valve spring retainer 7. Valve spring 8. Inlet valve <<B>> >>D<< 9. Valve spring retainer lock 10. Valve spring retainer 11. Valve spring 12. Exhaust valve <<C>> >>C<< 13. Valve stem seal >>C<< 14. Valve spring seat <<C>> >>C<< 15. Valve stem seal >>C<< 16. Valve spring seat 17. Inlet valve guide 18. Exhaust valve guide 19. Inlet valve seat 20. Exhaust valve seat >>B<< 21. Stud >>A<< 22. Stud 23. Cylinder head

caution Provide one punch mark on the head of the cylinder head bolt each time the bolt is tightened. replace the bolt that already has five punch marks (the evidence of having been tightened five times).

Using a 14 mm - 12 points socket wrench, loosen the cylinder head bolt. Loosen each bolt evenly, little by little, by two or three steps.

1.Set special tool valve spring compressor (MD998772) as illustrated to compress the valve spring. Remove the retainer lock. 2.Relieve the spring tension and remove the valve, retainer, spring, etc. Store removed valves, springs, and other parts, tagged to indicate their cylinder no. and location for assembly.

Use special tool valve stem seal pliers (MB992085) to nip the base of the stem seal (where the outside diameter is larger) securely, and remove it by twisting it to the left and right.

3.Special tool valve stem seal installer adjustable (MB992922) is composed of the components shown in the illustration. 1: Chuck 2: Sleeve 3: Rock nut (small) 4: Outer pipe 5: Rock nut (large) 6: Guide pin (5.9) 7: Guide pin (4.9) 8: Cap 9: Guide pin (5.4)

4.Adjust the inside chuck diameter, obeying the following procedures. (1) Install the sleeve to the chuck as shown in the illustration. (2) Install the shoulder of the valve stem seal to the chuck, aligning with the outer circumference line of the chuck as shown in the illustration. (3) Turn the sleeve to wring the chuck. (4) Stop the sleeve at the position where you can easily remove the valve stem seal by hand. (5) Use the (small) rock nut to fix the sleeve.

5.Adjust the stem seal insertion length [L (L1)], obeying the following procedures. (1) The position, in which the end face of the outer pipe is aligned with the outer circumference line of the chuck, is 0 mm of the insertion length. Insert the chuck and the sleeve into the outer pipe to fit the nut as shown in the illustration. (2) Turn the chuck to adjust the valve stem seal insertion length. note The insertion length can change by 1 mm per the chuck turn. To easily know how many times the chuck is turned, put the mark at the position shown in the illustration. (3) Use a vernier caliper to measure the checkpoint (L1) of the insertion length shown in the illustration. Check the insertion length. L1: 19.8 mm (4) Use the (large) rock nut to fix the sleeve.

6.Install the cap to the guide pin (5.9). 7.Install the guide pin (5.9) as shown in the illustration. 8.Apply the engine oil to the valve stem seal to set the chuck. 9.Install the valve spring seat.

10.Use the plastic hammer to insert the valve stem seal.

Compress the valve spring using special tool valve spring compressor (MD998772), them install the retainer lock.

1.In case any of the cylinder block, piston, connecting rod and crankshaft has not been replaced, install the gasket of the same rank as before which can be identified by the identification tab shown in the illustration.

2.In case any of the cylinder block, piston, connecting rod and crankshaft have been replaced, reselect and install the gasket in accordance with the following procedure. (1) With each piston held at the top dead centre, measure its protrusion from the upper block surface at the locations shown in the illustration at left (total of eight locations). Be sure to take measurements on the crankshaft centre line. (2) Using the average of the eight measurements, select the gasket rank (A, B or C) in accordance with the table given below. If, however, the maximum protrusion at any one location exceeds the protrusion tolerance shown for any rank in the following table, use the gasket one rank higher that rank. <Except high power engine> Rank Average value of piston protrusions mm Protrusion tolerance for each rank mm Thickness of selected gasket (when tightened) mm Identification tab A 0.06 - 0.12 0.17 0.95 ± 0.04 Non-equipped B 0.12 - 0.18 0.23 1.00 ± 0.04 C 0.18 - 0.24 - 1.05 ± 0.04 <High power engine> Rank Average value of piston protrusions mm Protrusion tolerance for each rank mm Thickness of selected gasket (when tightened) mm Identification tab A 0.06 - 0.12 0.17 1.07 ± 0.04 Equipped B 0.12 - 0.18 0.23 1.12 ± 0.04 C 0.18 - 0.24 - 1.17 ± 0.04 note If the piston projection exceeds the tolerance, replace the piston, connecting rod, crankshaft or cylinder block and check again.

1. caution Before installing the cylinder head bolt, check the number of punch marks on its head. (the bolt is reusable if it is four or less.) the number of punch marks corresponds to that to times the bolt has been tightened to the plastic area. if the bolt has five punch marks, replace it. Apply punch mark to the bolt head of the cylinder head bolt. 2.Set the cylinder head bolt washer with its shear droop toward the bolt head.

3.Apply engine oil to the bolt threads and washers. note Using a 14 mm - 12 points socket wrench.

4.Tighten the bolts to 78 ± 2 N·m in the indicated sequence. 5.Loosen all the bolts completely. 6.Tighten the bolts again to a torque of 29 ± 2 N·m in the indicated sequence. After that, confirm all bolts are reached to the specified torque, and then go to the next process.

7.Make paint marks on each bolt’s head and on the cylinder head. 8. caution When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure. Turn the bolts 90° in the tightening direction and in the indicated sequence. 9.Give another 90° turn in the tightening direction to each bolt, making sure that the paint mark on the bolt head and that on the cylinder head are on the same line.