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CHECKING THE CYLINDER HEAD
1. Eliminate:
• Carbon deposits (from the com-
bustion chambers)
Use a rounded scraper.
Do not use a sharp instrument to
avoid damaging or scratching:
• Spark plug threads
• Valve seats
2. Inspect:
• Cylinder head
Scratches/damage → Replace.
3. Measure:
• Cylinder head warpage
Out of specification → Resurface.
Cylinder head warpage:
Less than 0.05 mm
(0.002 in)
Warpage measurement and resur-
facing steps:
a. Place a straightedge and a feeler
gauge across the cylinder head.
b. Use a feeler gauge to measure
the warpage.
c. If the warpage is out of specifica-
tion, resurface the cylinder head.
d. Place a 400–600 grit wet sandpa-
per on the surface plate, and re-
surface the head using a figure-
eight sanding pattern.
To ensure an even surface rotate the
cylinder head several times.
INSTALLING THE CYLINDER
HEAD
1. Install:
• Timing chain guide (exhaust side)
"1"
• Dowel pin "2"
• Cylinder head gasket "3"
• Cylinder head "4"
While pulling up the timing chain, in-
stall the timing chain guide (exhaust
side) and cylinder head.
2. Install:
• Washer "1"
• Bolts "2"
Installation steps:
Tighten the cylinder head using
the rotation angle procedure to ob-
tain uniform tightening torque.
a. Wash the threads and contact
surfaces of the bolts, the contact
surfaces of the plain washers, the
contact surface of the cylinder
head, and the threads of the
crankcase.
b. Apply the molybdenum disulfide
grease on the threads and con-
tact surfaces of the bolts and on
both contact surfaces of the plain
washers.
c. Install the plain washers and
bolts.
d. Tighten the bolts to the specified
torque in two or three steps in the
proper tightening sequence as
shown.
Bolts (cylinder head):
1st:
30 Nm (3.0 m•kg, 22
ft•lb)
4-20
CYLINDER HEAD
e. Remove the bolts.
f. Again apply the molybdenum dis-
ulfide grease on the threads and
contact surfaces of the bolts and
on both contact surfaces of the
plain washers.
g. Retighten the bolts.
Tighten the bolts to the specified
torque in two or three steps in the
proper tightening sequence as
shown.
Bolts (cylinder head):
2nd:
20 Nm (2.0 m•kg, 14
ft•lb)
h. Put a mark on the corner "1" of the
bolt (cylinder head) and the cylin-
der head "2" as shown.
Tighten the bolts 90° in each of the
two steps to reach the specified angle
of 180° in the proper tightening se-
quence as shown.
Bolts (cylinder head):
Final:
Specified angle 180°

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  • nick Jan 26, 2016 10:47:
    The download is jacked up, so it's only really viewable on the site, but can't really complain since it's free.