4-20
ENGCYLINDER HEAD, CYLINDER AND PISTON
EC474000
INSPECTION
EC474102
Cylinder head
1. Eliminate:
9Carbon deposits
Use a rounded scraper 1.
NOTE:
Take care to avoid damaging the spark plug
threads. Do not use a sharp instrument. Avoid
scratching the aluminum.
2. Inspect:
9Cylinder head water jacket
Crust of minerals/Rust Remove.
9Cylinder head warpage
Out of specification Re-surface.
Warpage measurement and re-surface-
ment steps:
9Attach a straightedge 1and a thickness
gauge 2on the cylinder head.
9Measure the warpage.
9If the warpage is out of specification, resur-
face the cylinder head.
9Place # 400~600 grit wet sandpaper 3on
the surface plate, and re-surface the head
4using a figure-eight sanding pattern.
NOTE:
Rotate the cylinder head several times to
avoid removing too much material from one
side.
EC474201
Cylinder
1. Eliminate:
9Carbon deposits
Use a rounded scraper 1.
NOTE:
Do not use a sharp instrument. Avoid scratching
the aluminum.
Warpage limit:
0.03 mm(0.0012 in)
5XE-9-30-4B 3/24/03 11:18 PM Page 6
4-29
ENGCYLINDER HEAD, CYLINDER AND PISTON
7. Install:
9Cylinder head 1
9Copper washer 2
9Nut (cylinder head) 3
NOTE:
Tighten the nuts (cylinder head) in stage, using a
crisscross pattern.
8. Install:
9Engine bracket 1
9Bolt (engine bracket) 2
9CDI unit bracket 3
9Engine mounting bolt (upper) 4
9. Install:
9Spark plug 1
9Spark plug cap 2
9Radiator hose 2 3
28 Nm (2.8 m•kg, 20 ft•lb)
34 Nm (3.4 m•kg, 24 ft•lb)
34 Nm (3.4 m•kg, 24 ft•lb)
20 Nm (2.0 m•kg, 14 ft•lb)
5. Install:
9Gasket (power valve housing)
9Power valve housing 1
9Bolt (power valve housing) 2
6. Install:
9O-ring 1
NOTE:
Apply the lithium soap base grease on the O-
rings.
5 Nm (0.5 m•kg, 3.6 ft•lb)
1 Nm (0.1 m•kg, 0.7 ft•lb)
5XE-9-30-4B 3/24/03 11:18 PM Page 24
