Assembly

ASSEMBLY OF CYLINDER HEAD

NOTE:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets and oil seals with new ones.

1. INSTALL VALVES

(a) Install new oil seals on the valve guide bushings.

NOTE: Pushing down at the places shown in the illustration.

(b) Rotate the oil seal to check that it is firmly installed.

(d) Install the seats, springs and spring retainers on the cylinder head.
(e) Using SST, compress the valve retainers and place two keepers around the valve stem. SST 09202-70010
(f) Tap the stem lightly to assure proper fit.

2. (When replacing with a new cylinder head), install rocker arms.
Use a brass bar and hammer to install the valve rocker arm pivot onto the cylinder head.

3. INSTALL ROCKER ARMS
(a) Before installing the rocker arm, check that adjusting screw is as shown in the illustration.
(b) Install a new rocker arm spring to the rocker arm.

(c) Using a screwdriver, press the bottom lip of the rocker arm spring until it fits into the groove on the rocker arm pivot.

NOTE: Put the valve adjusting screw in the rocker arm pivot.

(d) Using a screwdriver, pry the rocker arm spring onto the rocker arm pivot.

(e) Pulling the rocker arm up and down, check that there is spring tension on to the rocker arm and that the rocker does not rattle.

4. INSTALL CAMSHAFT AND OIL SEAL

NOTE: To prevent the sub intake valve and the piston head from damage perform steps (a) and (c) below.

(a) Set No.1 cylinder to TDC/compression
(b) Coat all bearing journals with engine oil.
(c) With the knock pin in the 12 o'clock position, place the camshaft on the cylinder head.

(d) Place bearing caps on each journal with the arrows pointing toward the front.

(e) Apply engine oil to the lip of a new oil seal.

(f) Install a new oil seal.

NOTE: Be careful not to install the oil seal slantwise.

(g) Apply seal packing to the No.1 bearing cap as shown in the figure. Seal packing: Part No.08826-00080 or equivalent

NOTE: Install the No.1 bearing cap immediately after applying the seal packing.

(h) Place the bearing caps on the cylinder head.

(i) Torque each bearing cap bolts a little at a time in the sequence shown in the figure.
Torque: 140 kg-cm (10 ft-lb, 14 N.m)

(j) Check the camshaft thrust clearance. See step 23 in removal.
Standard clearance: 0.08-0.18 mm (0.0031 - 0.0071 in.)
Maximum clearance: 0.25 mm (0.0098 in.)

5. INSTALL INTAKE MANIFOLD
Install a new gasket and the manifold with the five bolts and nut. Torque the bolts and nut.
Torque: 195 kg-cm (14 ft-lb, 19 N.m)

6. INSTALL FUEL PUMP
Install two new gaskets, insulator and fuel pump with the two nuts.
Torque: 130 kg-cm (9 ft-lb. 13 N.m)

7. INSTALL AIR PIPE
(a) Install the air pipe with the bolt and nut.
Torque: 130 kg-cm (9 ft-lb, 13 N.m)
(b) Connect the vacuum hoses.
8. INSTALL NEW GASKETS AND CARBURETOR HEAT INSULATOR

9. INSTALL ACCELERATOR CABLE BRACKET AND AIR CLEANER BRACKET
Torque: 185 kg-cm (13 ft-lb, 18 N.m)
10. INSTALL CARBURETOR Carburetor Service and Repair.

11. INSTALL EXHAUST MANIFOLD
(a) Install the No.2 heat insulator, two new gaskets and manifold with the six nuts.

NOTE: Install the exhaust manifold gasket with the "E" mark facing outward.

(b) Torque the six nuts.
Torque: 520 kg-cm (38 ft-lb, 51 N.m)

(c) Install the No.1 heat insulator with three nuts.
Torque: 80 kg-cm (69 in.-lb, 7.8 N.m)
(d) (Calif.)
Install the AS pipe.

12. INSTALL NO.1 ENGINE HANGER
(a) Clean the bolt threads and cylinder head bolt hole of any sealer, oil or foreign material. Remove any oil with kerosene or gasoline.
(b) Apply sealant to 2 or 3 threads of the bolt end. Sealant: Part No.08833-00070, THREE BOND 1324 or equivalent. (c) Torque the bolt.
Torque: 210 kg-cm (15 ft-lb, 21 N.m

13. INSTALL NO.2 ENGINE HANGER Torque: 590 kg-cm (43 ft-lb, 58 N.m)

14. INSTALL WATER OUTLET HOUSING
(a) Remove any old packing material and be careful not to drop any oil on the contacting surfaces of the water outlet housing and cylinder head.
- Using a razor blade and gasket scraper, remove all the packing (FIPG) material from the gasket surfaces.
- Thoroughly clean all components to remove all the loose material.
- Clean both sealing surfaces with a nonresidue solvent.

CAUTION:Do not use a solvent which will affect the painted surfaces.

(b) Apply seal packing to the water outlet housing as shown in the figure. Seal packing: Part No.08826-00100 or equivalent
- Install a nozzle that has been cut to 2 mm (0.08 in.) opening.

NOTE: Avoid applying an excess amount to the surface. Be especially careful near oil passages.
- Parts must be assembled within 15 minutes of application. Otherwise, the material must be removed and re-applied.
- Immediately remove nozzle from tube and reinstall cap.

(c) Install the water outlet housing with the bolt and two nuts.
Torque: 175 kg-cm (13 ft-lb. 17 N.m)
15. INSTALL DISTRIBUTOR