CYLINDER HEAD REPLACEMENT

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for the Bank 2 side and Bank 1 side.

  • The following procedure is for the Bank 1 side.

PROCEDURE


  1. REPLACE NO. 2 INTAKE VALVE GUIDE BUSH


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

      CAUTION:

      B000VH0

      • Do not touch the cylinder head LH 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 LH on wooden blocks.

      CAUTION:

      Be sure to wear protective gloves.

    3. B000Y2VN02

      Using SST and a hammer, tap out the No. 2 intake valve guide bush.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
    4. B000YGZ

      Using a caliper gauge, measure the No. 2 intake valve guide bush bore diameter of the cylinder head LH.

      Standard Bush Bore Diameter
      10.285 to 10.306 mm (0.405 to 0.406 in.)

      If the No. 2 intake valve guide bush bore diameter of the cylinder head LH is more than 10.306 mm (0.4057 in.), machine the bush bore to a dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 No. 2 intake valve guide bush.

      If the bush bore diameter is 10.356 mm (0.408 in.) or more, replace the cylinder head LH.

    5. Select a new No. 2 intake valve guide bush (STD or O/S 0.05), and measure its diameter.

    6. Machine the bush bore to a diameter of the selected No. 2 intake valve guide bush.

      Bush Bore Diameter
      Bush Size Bush Bore Diameter
      STD

      10.285 to 10.306 mm

      (0.405 to 0.406 in.)
      O/S 0.05

      10.335 to 10.356 mm

      (0.407 to 0.408 in.)

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

      CAUTION:

      B000VH0

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

      • Be sure to wear protective gloves to avoid burns.

    8. B000U7BC01
      *a Height

      Using SST and a hammer, tap in a new No. 2 intake valve guide bush to the specified protrusion height.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Standard Protrusion Height
      14.3 to 14.7 mm (0.563 to 0.579 in.)
    9. B000XAA

      Using a sharp 5.5 mm reamer, ream the No. 2 intake valve guide bush to obtain the specified clearance between the No. 2 intake valve guide bush and valve stem.

  2. REPLACE NO. 2 EXHAUST VALVE GUIDE BUSH


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

      CAUTION:

      B000VH0

      • Do not touch the cylinder head LH 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 LH on wooden blocks.

      CAUTION:

      Be sure to wear protective gloves.

    3. B000UK1N02

      Using SST and a hammer, tap out the No. 2 exhaust valve guide bush.

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

    4. Using a caliper gauge, measure the No. 2 exhaust valve guide bush bore diameter of the cylinder head LH.

      Standard Cylinder Bore Diameter
      10.285 to 10.306 mm (0.405 to 0.406 in.)

      If the No. 2 exhaust valve guide bush bore diameter of the cylinder head LH is more than 10.306 mm (0.406 in.), machine the bush bore to a dimension of 10.335 to 10.356 mm (0.407 to 0.408 in.) to install an O/S 0.05 No. 2 exhaust valve guide bush.

      If the No. 2 exhaust valve guide bush bore diameter of the cylinder head LH is more than 10.356 mm (0.408 in.), replace the cylinder head LH.

    5. Select a new No. 2 exhaust valve guide bush (STD or O/S 0.05), and measure its diameter.

    6. Machine the bush bore diameter to a diameter of the selected No. 2 exhaust valve guide bush.

      Bush Bore Diameter
      Bush Size Bush Bore Diameter
      STD

      10.285 to 10.306 mm

      (0.4049 to 0.4057 in.)
      O/S 0.05

      10.335 to 10.356 mm

      (0.4069 to 0.4077 in.)

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

      CAUTION:

      B000VH0

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

      • Be sure to wear protective gloves to avoid burns.

    8. B000VSRN02

      Using SST and a hammer, tap in a new No. 2 exhaust valve guide bush to the specified protrusion height.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Standard Protrusion Height
      14.3 to 14.7 mm (0.563 to 0.579 in.)
    9. B000TTV

      Using a sharp 5.5 mm reamer, ream the No. 2 exhaust valve guide bush to obtain the specified clearance between the No. 2 exhaust valve guide bush and valve stem.

  3. REPLACE STRAIGHT PIN

    Note

    It is not necessary to remove the straight pins unless they are being replaced.


    1. Using a plastic hammer, tap in new straight pins to the specified protrusion height.

      B000YMYC03
      *A for Bank 1 *B for Bank 2
      *a Protrusion height - -
      Standard Protrusion Height
      8.0 to 10.0 mm (0.315 to 0.394 in.)

  4. REPLACE STUD BOLT

    Note

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


    1. Using E6 and E8 "TORX" socket wrenches, install the stud bolts.

      B000V57C01
      *a for Bank 2 Intake Side *b for Bank 1 Intake Side
      *c for Bank 2 Exhaust Side *d for Bank 1 Exhaust Side
      *e for Bank 2 Front Side *f for Bank 1 Front Side
      *g 12 mm (0.472 in.) *h 52 mm (2.05 in.)
      *i 24 mm (0.945 in.) *j 13 mm (0.512 in.)
      *k 45 mm (1.77 in.) *l 20 mm (0.787 in.)
      *m 35 mm (1.38 in.) *n 14 mm (0.551 in.)
      *o 29 mm (1.14 in.) *p 9 mm (0.354 in.)
      *q 19 mm (0.748 in.) - -
      Torque:
      Stud Bolt (A), (B), (C) and (D)
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
      Stud Bolt (E)
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }