1. Remove w/head taper screw plug no.2
2. Remove valve lifter
3. Remove valve
Sst 09202–70020 (09202–00010, 09202–01010, 09202–01020)
4. Valve stem oil o seal or ring
5. Remove valve spring seat
6. Remove stud bolt
7. Inspect cylinder head for flatness
Maximum warpage:
cylinder block side 0.05 Mm (0.0020 In.)
Intake manifold side 0.10 Mm (0.0039 In.)
Exhaust manifold side 0.10 Mm (0.0039 In.)
If the warpage is greater than maximum, replace the cylinder head.
8. Inspect cylinder head for cracks
9. Inspect valve seats
Notice
: do not rotate valve.
10. Repair valve seats
Notice
: take off a cutter gradually to make smooth valve seats.
11. Inspect camshaft thrust clearance
Standard thrust clearance: 0.040 – 0.095 Mm (0.0016 – 0.0037 In.) Maximum thrust clearance: 0.110 Mm (0.0043 In.)
If the thrust clearance is greater than maximum, replace the cylinder head. If damages are found on the camshaft thrust surfaces, the camshaft also has to be replaced.
12. Inspect camshaft oil clearance
otice
: do not turn the camshaft.
Standard oil clearance: 0.035 – 0.072 Mm (0.0014 – 0.0028 In.) Maximum oil clearance: 0.10 Mm (0.0039 In.)
Notice
: completely remove the plastigage after the measuring.
If the oil clearance is greater than maximum, replace the cylinder head.
13. Inspect valve lifter
Lifter diameter: 30.966 – 30.976 Mm (1.2191 – 1.2195 In.)
14. Inspect valve lifter oil clearance
Lifter bore diameter:
31.000 – 31.025 Mm (1.2205 – 1.2215 In.)
Standard oil clearance: 0.024 – 0.059 Mm (0.0009 – 0.0023 In.) Maximum oil clearance: 0.079 Mm (0.0031 In.)
If the oil clearance is greater than maximum, replace the valve lifter.
If necessary, replace the cylinder head.
15. Inspect inner compression spring
Free length: 43.40 Mm (1.7087 In.)
Maximum deviation: 1.6 Mm (0.063 In.) Maximum angle (reference): 2
if the deviation is greater than maximum, replace the inner compression spring.
Installed tension:
158.6 – 175.4 N (16.2 – 17.9 Kgf, 35.7 – 39.5 Lbf)
at 33.6 Mm (1.323 In.)
Maximum working tension:
335.3 – 370.7 N (34.2 – 37.8 Kgf, 75.4 – 83.3 Lbf)
at 24.1 Mm (0.949 In.)
If the installed tension is not as specified, replace the inner compression spring.
16. Inspect valve
Standard overall length: intake 88.65 Mm (3.4902 In.) Exhaust 88.69 Mm (3.4917 In.) Minimum overall length: intake 88.35 Mm (3.4784 In.) Exhaust 88.39 Mm (3.4799 In.)
If the overall length is less than minimum, replace the valve.
Valve stem diameter:
intake 5.470 – 5.485 Mm (0.2154 – 0.2159 In.)
Exhaust 5.465 – 5.480 Mm (0.2152 – 0.2158 In.)
Standard margin thickness: 1.0 Mm (0.039 In.) Minimum margin thickness: 0.7 Mm (0.028 In.)
If the overall length is less than minimum, replace the valve.
17. Inspect valve guide bushing oil clearance
Busing inside diameter: 5.510 – 5.530 Mm (0.2169 – 0.2177 In.)
Standard oil clearance:
intake 0.025 – 0.060 Mm (0.0010 – 0.0024 In.)
Exhaust 0.030 – 0.065 Mm (0.0012 – 0.0026 In.)
Maximum oil clearance:
intake 0.08 Mm (0.0032 In.)
Exhaust 0.10 Mm (0.0039 In.)
If the oil clearance is greater than maximum, replace the valve and valve guide bushing.
18. Replace valve guide bushing
Sst 09201–10000, 09201–01055, 09950–70010 (09951–07100)
Diameter: 10.285 – 10.306 Mm (0.4049 – 0.4058 In.)
If the bushing bore diameter of the cylinder head is greater than 10.306 Mm (0.4058 In.), Machine the bushing bore to the dimension of 10.335 – 10.356 Mm (0.4069 – 0.4077 In.) To install a over size valve guide bushing.
Hint:
Sst 09201–10000, 09201–01055, 09950–70010
(09951–07100)
protrusion height: 8.7 – 9.1 Mm (0.343 – 0.358 In.)
Standard oil clearance: intake 0.025 – 0.060 Mm (0.0010 – 0.0024 In.) Exhaust 0.030 – 0.065 Mm (0.0012 – 0.0026 In.)
19. Install straight pin
Standard protrusion: 5 mm (0.197 In.)
20. Install union
Adhesive:
part no. 08833–00070, Three bond 1324 or equivalent.
Standard protrusion:
a 29 mm (1.142 In.)
B 66.5 Mm (2.618 In.)
C 24 mm (0.945 In.)
Notice
:
21. Install stud bolt
22. Install valve spring seat
23. Install valve stem oil o seal or ring
Notice
: be very careful to assemble the oil seal for intake and exhaust.
Assembling the wrong one may cause a failure.
Hint
: the intake valve stem oil seal is gray and exhaust valve stem oil seal is black.
Sst 09201–41020
24. Install valve
Sst 09202–70020 (09202–00010, 09202–01010, 09202–01020)
Notice
: be careful not to damage the valve stem tip.
25. Install valve lifter
26. Install w/head taper screw plug no.2
Torque: 44 nvm (449 Kgf·cm, 33 ft·lbf)
Power point socket assy rr
Replacement
Hint: components:
1. Remove parking brake hole cover sub–assy
2. Remove floor shift shift lever knob sub–assy (m/t transaxle)
3. Remove console panel upper
4. Remove console box carpet
5. Remove console box sub–assy rear (m/t transaxle)
6. Remove console box sub–assy rear (a/t tr ...
Displays and control
elements
In the vicinity of the steering
wheel
Light switch element
Turn signal indicator, high beams
Instrument cluster
Wipers
Start/Stop button
Indicator/warning lights
Instrument cluster
The indicator/warning lights can light up in a variety
of combinations and colors.
Several of the lights are c ...
Body panel sealing areas
Be sure to apply body sealer to the body panel joints and door edges (tip of
outer panel folded part), etc., To waterproof
and rustproof them.
Hint:
apply degreasing agent to a clean cloth and clean the sealer
application areas.
After removing the applied spot sealer from the se ...