CYLINDER HEAD(w/o Glow Plug Controller) REPLACEMENT

PROCEDURE


  1. REPLACE INTAKE VALVE GUIDE BUSH


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

    2. B0041PQE01

      Using SST and a hammer, tap out the intake valve guide bush to the combustion chamber side.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010
    3. B0043N5

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

      Standard bush bore diameter
      10.985 to 11.006 mm (0.4325 to 0.4333 in.)

      Tech Tips


      • If the intake valve guide bush bore diameter is as specified, install a standard intake valve guide bush.

      • If the intake valve guide bush bore diameter is not as specified, machine the bush bore to 11.035 to 11.056 mm (0.4345 to 0.4353 in.) and install an oversize intake valve guide bush.

        Bush Size Bush Bore Diameter mm (in.)
        Standard Standard 10.985 to 11.006 (0.4325 to 0.4333)
        Oversize (0.05) Oversize 11.035 to 11.056 (0.4344 to 0.4353)

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

    5. B0043EOE01

      Using SST and a hammer, tap in a new intake valve guide bush to the specified protrusion height.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010
      Standard protrusion height
      15.9 to 16.7 mm (0.626 to 0.657 in.)
    6. B004292

      Using a reamer, ream the inside of the intake valve guide bush to obtain the specified oil clearance.

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

  2. REPLACE EXHAUST VALVE GUIDE BUSH


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

    2. B0044BFE01

      Using SST and a hammer, tap out the exhaust valve guide bush to the combustion chamber side.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010
    3. B00452P

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

      Standard bush bore diameter
      10.985 to 11.006 mm (0.4325 to 0.4333 in.)

      Tech Tips


      • If the exhaust valve guide bush bore diameter is as specified, install a standard exhaust valve guide bush.

      • If the exhaust valve guide bush bore diameter is not as specified, machine the bush bore to 11.035 to 11.056 mm (0.4344 to 0.4353 in.) and install an oversize exhaust valve guide bush.

        Bush Size Bush Bore Diameter mm (in.)
        Standard Standard 10.985 to 11.006 (0.4325 to 0.4333)
        Oversize (0.05) Oversize 11.035 to 11.056 (0.4344 to 0.4353)

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

    5. B0042NTE01

      Using SST and a hammer, tap in a new exhaust valve guide bush to the specified protrusion height.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010
      Standard protrusion height
      15.9 to 16.7 mm (0.626 to 0.657 in.)
    6. B0043ZJ

      Using a reamer, ream the inside of the exhaust valve guide bush to obtain the specified oil clearance.

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

  3. REPLACE RING PIN


    1. Remove the 4 ring pins shown in the illustration.

    2. B0041N3N01
      *1 mm (in.)
      *2 4.0 to 5.0
      *3 (0.157 to 0.197)

      Using a plastic-faced hammer, tap in 4 new ring pins to the specified protrusion height.

  4. REPLACE STRAIGHT PIN


    1. Remove the straight pin shown in the illustration.

    2. B0044ZBN02

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

  5. REPLACE STUD BOLT


    1. Using an E6, E8 and E10 "TORX" socket wrench, remove the 17 stud bolts.

    2. Using an E6, E8 and E10 "TORX" socket wrench, install the 17 stud bolts.

      B0041WVC01
      *a Front Side *b Exhaust Side
      *c Rear Side *d Intake Side
      Torque:
      Stud Bolt A, D
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Stud Bolt B
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }
      Stud Bolt C
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }