CYLINDER HEAD REPLACEMENT

PROCEDURE


  1. REPLACE INTAKE VALVE GUIDE BUSH


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

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

    3. A01D4B6N06

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
    4. A012JIF

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

      Standard bush bore diameter
      10.285 to 10.306 mm (0.4049 to 0.4057 in.)
      New Guide Bush Selection Chart (STD or O/S 0.05)
      Bush Size Bush Bore Diameter
      STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
      O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.)

      If the bush bore diameter of the cylinder head sub-assembly is greater than 10.344 mm (0.4072 in.), machine the bush bore to the diameter of 10.383 to 10.394 mm (0.4088 to 0.4092 in.) to install an O/S 0.05 intake valve guide bush. If the bush bore diameter of the cylinder head sub-assembly is greater than 10.394 mm (0.4092 in.), replace the cylinder head sub-assembly.

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

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

    7. A01D504C04
      *a Height

      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   ( 09951-07100 )
      Standard protrusion height
      9.9 to 10.3 mm (0.3898 to 0.4055 in.)
    8. A01D4O5

      Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard clearance between the intake valve guide bush and valve stem.

      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 80 to 100°C (176 to 212°F).

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

    3. A01D5TJN05

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
    4. A01D42J

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

      Standard bush bore diameter
      10.285 to 10.306 mm (0.4049 to 0.4057 in.)
      New Guide Bush Selection Chart (STD or O/S 0.05)
      Bush Size Bush Bore Diameter
      STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
      O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.)

      If the bush bore diameter of the cylinder head sub-assembly is greater than 10.344 mm (0.4072 in.), machine the bush bore to the diameter of 10.383 to 10.394 mm (0.4088 to 0.4092 in.) to install an O/S 0.05 exhaust valve guide bush. If the bush bore diameter of the cylinder head sub-assembly is greater than 10.394 mm (0.4092 in.), replace the cylinder head sub-assembly.

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

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

    7. A01D5SFC04
      *a Height

      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   ( 09951-07100 )
      Standard protrusion height
      11.15 to 11.55 mm (0.4390 to 0.4547 in.)
    8. A01D434

      Using a sharp 5.5 mm reamer, ream the exhaust valve guide bush to obtain the standard oil clearance between the exhaust valve guide bush and valve stem.

      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 pins unless they are being replaced.


    1. A01D4IYC06
      *a Protrusion Height
      *b Height
      *c Width

      Remove the ring pins.

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

      Standard Ring Pin
      Item Height Width Protrusion
      Ring pin 11.7 to 12.3 mm (0.461 to 0.484 in.) 12.0 mm (0.472 in.) 6.5 to 7.5 mm (0.256 to 0.295 in.)

  4. REPLACE STUD BOLT

    Note

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


    1. Using an E8 "TORX" socket, install the stud bolts.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
      A01D5NGC03
      *a Intake Side *b Exhaust Side