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UNIT REPAIR

ylinder Head and Valve Train Components

ools Required

916-14510 Valve Spring Compressor916-37320 Valve Guide Reamer916-38210 Valve Guide Reamer916-44910 Volve Guide Remover916-48210 Valve Spring Compressor Attachment916-58210 Valve Guide Installer917-88220 Valve Guide Installer Attachment

M 412 Engine Overhaul Stand

sassembly Procedure

1. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "CylinHead and Gasket" in this section.

2. Remove the bolt and the nuts in the water outlet case .3. Remove the water outlet case.

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4. Remove the exhaust manifold heat shield bolts.5. Remove the exhaust manifold heat shield.

6. Remove the exhaust manifold nuts and the bolts.7. Remove the exhaust manifold gasket.8. Remove the exhaust manifold studs.

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9. Remove the spark plugs.

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0. Remove the intake manifold retaining bolts and the nuts.1. Remove the intake manifold with the gasket.2. Remove the intake manifold studs.

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3. Remove the rocker arm shaft mounting bolts.

4. Remove the rocker arm spring and the rocker arm.

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5. Remove the screws with the camshaft thrust plate.

6. Remove the camshaft.

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7. Remove the camshaft front oil seal from housing hole.

8. Using the valve spring compressor 09916-14510, compress the valve spring9. Remove the valve keepers.0. Remove the valve spring retainer and valve spring.1. Remove the valves.

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2. Remove the valve stem oil seals.3. Remove the valve spring seat.

4. Position the valve guide remover 09916-44910 on the valve guide.5. Hammer and remove the valve guide from the combustion chamber to the direction of the installed va

spring using the valve guide remover 09916-44910.6. Remove the valve guide.

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ylinder Head Inspection

1. Clean the sealing surfaces.2. Inspect the cylinder head gasket and the mating surfaces for leaks, corrosion, and blowby.3. Inspect the cylinder head for cracks.4. Inspect the length and the width of the cylinder head using a feeler gauge and a straight edge.5. Check the sealing surfaces for deformation and warpage. The cylinder head sealing surfaces must be

with in 0.05mm (0.0020 in.) maximum.

6. Inspect all threaded holes for damage.

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7. Inspect the valve seats for excessive wear and burned spots.

alve Inspection

1. Inspect valve stem tip wear.2. Inspect the valve keeper grooves and oil seal grooves for chips and wear.3. Inspect the valves for burns or cracks.

4. Inspect the valve stem for burrs and scratches.5. Inspect the valve stem. The valve stem must be straight.6. Inspect the valve facefor grooving. If the groove is so deep the refacing would result in a sharp edge,

replace the valve.

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7. Inspect the valve spring. If the valve spring ends are not parallel, replace the valve spring.8. Measure the valve spring height. Refer to "Engine Specifications" in this section. If the valve spring h

does not match the specifications, replace the valve spring.9. Inspect the valve spring seating surface of the valve rotators for wear or gouges. Replace as required

eaning Procedure

1. Clean the cylinder head.2. Clean the valve guides.3. Clean all of the threaded holes.4. Clean the valves of carbon, oil and varnish.

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ylinder Head Overhaul

easuring The Camshaft Bend

1. Measure the bending of the camshaft using a dial gauge and replace it when the measured value is othe specified limit (0.03mm (0.0012 in.)).

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brasion of The Camshaft Journal

1. Measure the outer diameter of each journal at the 5 different places.

2. Using a bore gauge, measure the inner diameter of the cylinder head jornal at the 5 places (The cleaance of journal is measured by the difference be-tween the outer diameter of camshaft journal and indiameter of cylinder head journal part.)

3. Replace the camshaft (or cylinder head, if necessary) of which limit is over the specified limit.

Item Standard Limit

JournalClearance

0.05-0.091 mm(0.0020-0.0036 inches)

0.15 mm(0.0059 inches)

Item Outer diameter,camshaft journal

Inner diameter cylinder head journal pa

a 43.425-43.450 mm(1.7096-1.7106 in.)

43.500-43.516 mm(1.7126-1.7132 in.)

b 43.625-43.650 mm(1.7175-1.7185 in.)

43.700-43.716 mm(1.7205-1.7211 in.)

c 43.825-43.850 mm(1.7254-1.7264 in.)

43.900-43.916 mm(1.7283-1.7290 in.)

d 44.025-44.050 mm(1.7333-1.7343 in.)

44.100-44.116 mm(1.7362-1.7369 in.)

e 44.225-44.250 mm(1.741-1.742 in.)

44.3-44.316 mm(1.744-1.745 in.)

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ending of The Rocker Arm Shaft

1. Check the bending of the rocker arm shaft by using the V block and dial gauge.2. Replace the rocker arm shaft of which bending is over the specification (0.10mm (0.0039 inches)).

earance Between The Rocker Arm and The Rocker Arm Shaft

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1. Check the outer diameter of the rocker arm shaft using a micrometer.

2. Check the inner diameter of the rocker arm using a bore gauge.3. Replace the shaft or rocker arm (or both of them, if necessary) if the difference is over the limit betwe

the outer diameter and the inner diameter (0.005 - 0.040mm (0.0002 - 0.0016 in.)

earance Between The Valve Stem and The Valve Guide

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1. Check the outer diameter of the valve stem using a micrometer. Intake : 5.465 - 5.480mm (0.2152 - 0.2157 in.) Exhaust : 5.440 - 5.455mm (0.2142 - 0.2148 in.)

2. Check the inner diameter of the valve guide using a bore gauge (at least 1 place in the direction to valength)

Intake : 5.500 - 5.512mm (0.2165 - 0.2170 in.) Exhaust : 5.500 - 5.512mm (0.2165 - 0.2170 in.)

3. Check the clearance between the valve stem and the valve guide Intake : 0.020 - 0.047mm (0.0008 - 0.0019 in.) Exhaust : 0.0045 - 0.072mm (0.0018 - 0.0028 in.)

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4. If a bore gauge is not available, measure the clearance using a dial gauge by moving the edge of thestem to the directions.

Intake : 0.14mm (0.0055 in.) Exhaust : 0.18mm (0.0071 in.)

5. Replace the valve stem or valve guide, if the measured valve is over the limit.

alve

1. Inspect the valve. Refer to Valve Inspection in this section.2. Check the valve or stem for abrasion, burn or bending, and replace as necessary.3. Abrasion of the valve edge.

Check the edge of each valve for abrasion. Some uneven abrasion would be made on the edgebecause the rocker arm gets contacted at this surface when operating. Repair the section within0.05mm (0.002 in.) as required, or replace the valve if some modification is required more than

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4. Deviation to the rotating direction. Measure the deviation to the rotating direction using a dial gauge athe V block by turning the valve slowly. Deviation limit of valve head to the rotating direction within0.08mm (0.0031 in.)

5. Replace valve, if the measured value exceeds the limit.

6. Clean the valve and the valve seat and apply red stamping ink thinly to the contacting surface of the vseat. Check the fitness after installing the valve unit.

7. Check the contact witdth on the surface of the valve seat. Intake : 1.46 - 1.66mm (0.0575 - 0.0654 in.)

Exhaust : 1.46 - 1.66mm (0.0575 - 0.0654 in.)

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8. Repair by grinding and cutting off the valve seat, and lap it if its contacting width is not even or out of specified.

9. Upon applying a seat cutter, use the one of smaller angle first and increase the angle of the using cuup to the light and final modification of the contact. And finish contact surface and its location with thecutter of 45 degrees.

Important : Upon cutting, take care of the contact width. Finish the cutting with gradually redu

power for no cutting mark on the surface.

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0. Make lapping in two stages, first with normal lap and second with fine one for the both sides.

ssembly Procedure

1. Make the valve guide hole using a valve guide reamer 09916-38210. Before Installing The new valve

guide into the cylinder head, ream guide hole with 11mm reamer to remove burrs. Make sure that theguide hole cones to a complete roundness

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2. Peen and install new valve guide

Caution : Heat the cylinder head uniformly at a temperature 80-100C (176-212F) not to make head deformed, and drive new valve guide completely into the hole with the tools the valve guinstaller attachment 09917-88220.

3. Check the protruded part of the guide from the cylinder head.

Important : Do not reuse the valve guide once disassembled, replace it with the new oversizedvalve guide.

Valve guide oversize : 0.03mm (0.0012 in.) Valve guide protrusion : 14mm (0.5512 in.)

4. Repair the valve guide bore with the valve guide reamer 09916-37320 (5mm or 0.1969 in.)5. Make the hole free from foreign material.

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6. Install the valve spring seats.7. Install the valve stem oil seal to the valve guide. After applying engine oil to seal and installing seal to

valve guide and make sure that seal is properly fixed to the valve guide.

Important : Do not reuse the disassembled oil seal and replace it with new one. When installinneer tap or hit tool with a hammer or else. Install seal to guide only by pushing special tool wihand. Tapping or hitting tool may cause damage on seal.

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8. Install the valve to the valve guide.

Important : Before installing it, coat engine oil to the stem seal, valve guide bore and valve ste

9. Install the valve springs and the spring retainers.0. Using the valve spring compressor 09916-48210, compress the valve spring1. Install the valve keepers.

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2. Install the camshaft front oil seal from housing hole.

3. Coat the engine oil to the camshaft front oil seal, the cam, and the camshaft journal.4. Install the camshaft front oil seal to the housing hole.5. Install the camshaft to the cylinder head.

Notice : Installing the camshaft, take extreme care to prevent any screatch, nick or damage.

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6. Install the screws with the camshaft thrust plate.

TightenTighten the screws to 10 Nm (89 lb-in).

7. Coat the engine oil to the rocker arms and the rocker rocker arm shafts.8. Install the rocker arm spring and the rocker arm.

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9. Install the rocker arm shaft mounting bolts.

TightenTighten the bolts to 10 Nm (89 lb-in).

Important : Rocker arm shaft for the intake valves and the exhaust valves are different and thedirections of installation are different.

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0. Install the intake manifold studs.1. Install the intake manifold with the gasket.2. Install the intake manifold.

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3. Install the intake manifold nuts in the sequent order.

TightenTighten the intake manifold nuts and the bolts to 17 Nm (13 lb-ft).Tighen the intake manifold supprot bracket bolt to 10 Nm (89 lb-in).

Important : Before tightening the intake manifold nuts, first of all, tighten the intake manifoldsupport bracket nut.

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4. Install the spark plugs.

5. Install the exhaust manifold gasket and the exhaust manifold.

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6. Install the bolts and nuts in the sequent order as shown in the picture.

TightenTighten the exhaust manifold nuts and bolts to 22 Nm (16 lb-ft).

7. Install the exhaust manifold heat shield.8. Install the exhaust manifold heat shield bolts.

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TightenTighten the exhaust manifold heat shield bolts to 10 Nm (89 lb-in).

9. Install the water outlet case.0. Install the water outlet case mounting bolts.

Tighten

Tighen the water outlet case mounting bolts to 10.5 Nm (93 lb-in).

1. Install the cylinder head with the intake manifold and exhaust manifold attached. Refer to "Cylinder Hand Gasket" in this section.

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rankshaft

ools Required

M-412 Eneine Overhaul Stand916-77310 Piston Compressor

sassembly Procedure

1. Removethe engine. Refer to "Engine" in this section.2. Remove the transaxle from the engine. Refer to Section 5B, Five-Speed Manual Transaxle.3. Remove the flywheel bolts.4. Remove the flywheel.5. Mount the engine assembly on the engine overhaul stand KM-412.

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6. Remove the cylinder head. Refer to "Cylinder Head and Gasket" in this section.7. Drain the engine oil from the engine.8. Remove the power steering adjusting bolts.9. Remove the power steering/air conditioning belt.

0. Turn the A/C compressor downward.1. Remove the A/C compressor/power steering bracket bolts.

2. Remove the A/C compressor/power steering bracket.

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3. Loosen the generator bolt.4. Loosen the generator lower bolts and the nut.5. Remove the generator and belt.

6. Loosen the engine mount upper bracket bolts.7. Remove the generator shackle.8. Remove the upper bracket.9. Loosen the engine mount lower bracket bolts.

0. Remove the lower bracket.

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1. Remove the upper timing belt cover bolts.2. Remove the upper timing belt cover.

3. Remove the lower timing belt cover bolts.4. Remove the lower timing belt cover.

5. Loosen the timing belt automatic tensioner bolt.6. Remove the automatic tensioner from the timing belt.

7. Remove the timing belt.

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8. Rotate the engine on the engine overhaul stand KM-412.9. Remove the oil pan retaining bolts and the nuts.0. Remove the oil pan.

1. Remove the oil pan pickup tube bolts.2. Remove the oil pan pickup tube.

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3. Remove the oil pump retaining bolts.4. Remove the oil pump.

5. Remove the crankshaft rear oil seal housing screws and bolts.6. Remove the gasket and the oil seal housing.

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7. Mark the order of the rod bearing caps.8. Remove the connecting rod cap nuts for all of the pistons.9. Remove the connecting rod bearing caps and the lower connecting rod bearing.0. Remove the upper connecting rod bearing.

1. Mark the order of the crankshaft bearing caps.2. Remove the crankshaft bearing cap bolts.3. Remove the crankshaft bearing cap.4. Remove the crankshaft bearings from the crankshaft bearing caps.

5. Remove the crank shaft.

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6. Remove the crankshaft bearings from the engine block.7. Clean the parts, as necessary.

ssembly Procedure

1. With crankshaft and bearings in place, plastic gauge all bearing clearances. Refer to "CrankshaftBearings and Connecting Rod Bearings - Gauging Plastic" in this section.

2. Inspect the crankshaft end play with the crankshaft bearings installed.3. Check the Permissible crankshaft end play. Refer to "Engine Specifications" in this section.

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4. With the crankshaft mounted on the front and the rear crankshaft bearings, Check the middle cranksh

journal for permissible out-of-round (runout). Refer to "Engine Specifications" in this section.

5. Coat the crankshaft bearings with engine oil.6. Apply a bead of adhesive sealing compound to the grooves of the rear crankshaft bearing cap.7. Install the crankshaft bearings in the engine block.8. Install the crankshaft.

Important : Important : Grease the crankshaft journals and lubricate the crankshaft bearings

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slightly so that the plastic gauging thread does not tear when the crankshaft bearing caps areremoved.

9. Inspect all of the crankshaft bearing clearances using a commercially available plastic gauging (ductiplastic threads).

0. Cut the plastic gauging threads to the length of the bearing width. Lay them axially between thecrankshaft journals and the crankshaft bearings.

1. Install the crankshaft bearings to the crankshaft bearing caps.

2. Install the crankshaft bearing caps bolts.

Notice : Do not reuse the old crankshaft bearing cap bolts. Damage to the engine could result

TightenTighten the crankshaft bearing cap bolts to 57 Nm (42 lb-ft).

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3. Remove the crankshaft bearing caps.4. Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging

available for different tolerance ranges.)5. Inspect the bearing clearances for permissible tolerance ranges. Refer to "Engine Specifications" in t

section.

spection Precedure - Connecting Rods

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8. Remove the connecting rod bearing caps.9. Measure the width of th flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging i

available for different tolerance ranges.)0. Inspect the bearing clearance for permissible tolerance ranges. Refer to "Engine Specifications" in th

section.

spection Precedure - Piston

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1. Inspect the connecting rod for bending or twisting. If the connecting rod is bent or twisted, replace theconnecting rod.

2. Inspect the connecting rod bearings.3. Inspect the connecting rod lower end for wear.4. Inspec the connecting rod upper end for scoring.5. Inspect the piston for scoring, cracks and wear.6. Inspect pistion for taper using a micrometer.

7. Inspect the piston for fit to the connecting rod.

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8. Inspect the engine block deck surface for flatness using a straight edge and a feeler gauge. Refer to"Engine Specifications" in this section.

9. Inspect the bearing bore for concentricity and alignment using a bore gauge. Refer to "EngineSpecifications" in this section.

0. Inspect the engine block cylinder bore for wear, runout ridging and taper using a bore gauge. Refer to"Engine Specifications" in this section.

1. Inspect the engine block cylinder bore for glazing. Lightly hone the cylinder bore as necessary.

stallation Procedure

1. Align the notch on the piston and connecting rod so that the proper sides will be facing the front of theengine.

2. Install the pistion pin guide through the piston and the connecting rod.3. Coat the piston pin with clean oil.4. Install the piston pin into the opposite side of the pistion.5. Install the pistion pin into the pistion and connecting rod assembly.

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6. Select a set of new pistion rings.7. Measure the piston ring gap using a feeler gauge.8. Increase the piston ring gap by carefully filling off excess material if the piston ring gap is below

specifications.

9. Measure the pistion ring side clearance using a feeler gauge. Refer to "Engine Specifications" in thissection.

0. If the pistion ring is too thick, try another pistion ring.1. If no piston ring can be found that fits to specifications the pistion ring may be ground to size with em

paper placed on a sheet of glass.

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2. Install a piston oil ring, the expander and the second piston oil ring to the bottom ring groove of thepistion.

3. Install the second compression ring to the middle ring groove of the piston.4. Install the top compression ring to the top ring groove of the pistion.

5. Use a piston ring expander to install the piston rings. Do not expand the piston rings beyond theexpansion necessary for installation.

6. Stagger the piston oil rings, the oil ring rail gaps, the second compression ring, and the top compress

ring in relation to the notch on the top of the pistion.

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7. Lubricate the cylinder wall and the pistion rings with clean engine oil.8. Install the piston using a ring compressor and a wood handle. Guide the lower connecting rod end to

prevent damaging the crankshaft journal.9. Install the connecting rod cap and the bearing. Refer to "Crankshaft Bearings and Connecting Rod

Bearings - Gauging Plastic" in this section.

0. Install the connecting rod bearing cap nuts.

Tighten

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Tighten the connecting rod bearing cap nuts to 33 Nm (24 lb-ft).

1. Install the oil pump/pickup tube.2. Install the oil pump pickup tube bolts.

TightenTighten the oil pump pickup tube bolts to 10 Nm (89 lb-in).

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3. Install the oil pan.4. Install the oil pan bolts and nuts.

TightenTighten the oil pan bolts and nuts to 10 Nm (89 lb-in).

5. Install the lower engine mount bracket and the generator with the bolts

TightenTighten the lower engine mount bracket bolts to 38 Nm (28 lb-ft).

6. Install the upper engine mount bracket and the generator shackle with the bolts.

TightenTighten the upper engine mount bracket and generator shackle bolts to 38 Nm (28 lb-ft).

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7. Install the generator with the bolts and the nut.8. Install the generator belt.

TightenTighten the generator lower bolts and the nut to 23 Nm (17 lb-ft).Tighten the generator belt tension adjusting bolt to 23 Nm (17 lb-ft).

9. Install the engine mount bracket.

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0. Install the A/C compressor/Power steering Pump and the bracket with the bolts.

TightenTighten the engime mount bracket bolts to 20 Nm (15 lb-ft).Tighten the A/C compressor/Power steering Pump bracket bolts to 38 Nm (28 lb-ft).

1. Install the power steering pump bracket with the bracket bolt/nut and adjusting bolt.

TightenTighten the adjusting bolt and the power steering rear bracket nut to 22 Nm (16 lb-ft).

2. Install the power steering/air conditioning belt.3. Install the cylinder head with the intake manifold, the exhaust manifold, and distributor/adaaptor attac

Refer to "Cylinder Head and Gasket" in this section.4. Install the timing belt and component. Refer to "Timing Belt" in this section.5. Install the clutch and the transaxle to the engine then engine assembly to the engine compartment. R

to " Engine Assembly" in this section.

6. Refill the engine coolant system. Refer to Section 1D, Engine Cooling.7. Bleed the power steering system as necessary. Refer to Section 6A, Power Steering System.8. Refill the A/C refrigerant system as necessary. Refer to Section 7B, Manual Control Hearing, Ventilat

and Air Conditioning System.9. Refill the transaxle oil as necessary.0. Connect the negative battery cable.1. Start the engine and operate all systems.2. Operate the idle air contril valve reset procedure as necessary.

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