CYLINDER HEAD REPLACEMENT

PROCEDURE


  1. REPLACE INTAKE VALVE GUIDE BUSH LH


    1. Heat the cylinder head sub-assembly to 80 to 100°C (176 to 212°F).

      CAUTION:

      B006FE7

      • Do not touch the cylinder head sub-assembly without wearing protective gloves, as it may get very hot during operation.

      • Be sure to wear protective gloves to avoid burns.

    2. Place the cylinder head sub-assembly on wooden blocks.

      CAUTION:

      Be sure to wear protective gloves.

    3. B006A6TN02

      Using SST and a hammer, tap out the intake valve guide bushes.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )

    4. Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head sub-assembly.

      Standard cylinder bore diameter
      10.285 to 10.306 mm (0.405 to 0.406 in.)
      Select a New Guide Bush (STD or O/S 0.05)
      Bush Size Specified Condition
      STD 10.333 to 10.344 mm (0.40681 to 0.40724 in.)
      O/S 0.05 10.383 to 10.394 mm (0.40878 to 0.40921 in.)

      If the bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.406 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.407 to 0.408 in.) to install an O/S 0.05 valve guide bush.

      If the bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.408 in.), replace the cylinder head sub-assembly.

    5. Heat the cylinder head sub-assembly to 80 to 100°C (176 to 212°F).

      CAUTION:

      B006FE7

      • Do not touch the cylinder head sub-assembly without wearing protective gloves, as it may get very hot during operation.

      • Be sure to wear protective gloves to avoid burns.

    6. Place the cylinder head sub-assembly on wooden blocks.

      CAUTION:

      Be sure to wear protective gloves.

    7. B006CH8C02
      *a Protrusion Height

      Using SST, tap in new intake valve guide bushes to the specified protrusion height.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Standard protrusion height
      19.35 to 19.60 mm (0.762 to 0.772 in.)
    8. B006A6X

      Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.

      Standard oil clearance
      0.025 to 0.060 mm (0.000984 to 0.00236 in.)

  2. REPLACE EXHAUST VALVE GUIDE BUSH LH


    1. Heat the cylinder head sub-assembly to 80 to 100°C (176 to 212°F).

      CAUTION:

      B006FE7

      • Do not touch the cylinder head sub-assembly without wearing protective gloves, as it may get very hot during operation.

      • Be sure to wear protective gloves to avoid burns.

    2. Place the cylinder head sub-assembly on wooden blocks.

      CAUTION:

      Be sure to wear protective gloves.

    3. B006EINN02

      Using SST and a hammer, tap out the exhaust valve guide bushes.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )

    4. Using a caliper gauge, measure the exhaust valve guide bush bore diameter of the cylinder head sub-assembly.

      Standard cylinder bore diameter
      10.285 to 10.306 mm (0.405 to 0.406 in.)
      Select a New Guide Bush (STD or O/S 0.05)
      Bush Size Specified Condition
      STD 10.333 to 10.344 mm (0.40681 to 0.40724 in.)
      O/S 0.05 10.383 to 10.394 mm (0.40878 to 0.40921 in.)

      If the bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.406 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.407 to 0.408 in.) to install an O/S 0.05 valve guide bush.

      If the bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.408 in.), replace the cylinder head sub-assembly.

    5. Heat the cylinder head to 80 to 100°C (176 to 212°F).

      CAUTION:

      B006FE7

      • Do not touch the cylinder head sub-assembly without wearing protective gloves, as it may get very hot during operation.

      • Be sure to wear protective gloves to avoid burns.

    6. Place the cylinder head sub-assembly on wooden blocks.

      CAUTION:

      Be sure to wear protective gloves.

    7. B006E4ZC02
      *a Protrusion Height

      Using SST, tap in new exhaust valve guide bushes to the specified protrusion height.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Standard protrusion height
      19.75 to 20.0 mm (0.778 to 0.787 in.)
    8. B006ES6

      Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.

      Standard oil clearance
      0.030 to 0.065 mm (0.00118 to 0.00256 in.)

  3. REPLACE RING PIN

    Note

    It is not necessary to remove the ring pin unless it is being replaced.


    1. B006BXEC02
      *a for Bank 1
      *b for Bank 2
      *c Protrusion Height
      *d 5.5 to 6.5 mm (0.217 to 0.256 in.)
      *e 4.5 to 5.5 mm (0.177 to 0.217 in.)
      B006AHR Ring Pin A
      B006EC9 Ring Pin B

      Using a plastic-faced hammer, tap in new ring pins to the specified protrusion height.

      Standard protrusion height
      Ring pin A
      5.5 to 6.5 mm (0.217 to 0.256 in.)
      Ring pin B
      4.5 to 5.5 mm (0.177 to 0.217 in.)

  4. REPLACE STUD BOLT

    Note

    If the stud bolt is deformed or the threads are damaged, replace it.


    1. B006DSEC02
      *a for Bank 1
      *b for Bank 2
      *c 26.5 mm (1.04 in.)
      *d 20 mm (0.787 in.)
      *e 50 mm (1.97 in.)

      Using E10 "TORX" socket wrench, install the stud bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }