CYLINDER HEAD REPLACEMENT

PROCEDURE


  1. REPLACE INTAKE VALVE GUIDE BUSH


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

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

      CAUTION:

      Be sure to wear protective gloves.

    3. B006PH0N10

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
    4. B006NMS

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

      Standard Intake Valve Guide Bush Bore Diameter
      10.285 to 10.306 mm (0.4049 to 0.4057 in.)
      New Guide Bush Selection Chart
      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.)

      Tech Tips


      • If the intake valve guide bush bore diameter is more than 10.306 mm (0.4057 in.), machine the intake valve guide 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 intake valve guide bush.

      • If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.4077 in.), replace the cylinder head sub-assembly.

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

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

      CAUTION:

      Be sure to wear protective gloves.

    7. B006N94C04
      *a Protrusion 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
      9.30 to 9.70 mm (0.3661 to 0.3819 in.)
    8. B006N2V

      Using a sharp 5.5 mm reamer, ream 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 to 212°F).

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

      CAUTION:

      Be sure to wear protective gloves.

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
    4. B006P3B

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

      Standard Exhaust Valve Guide Bush Bore Diameter
      10.285 to 10.306 mm (0.4049 to 0.4057 in.)
      New Guide Bush Selection Chart
      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.)

      Tech Tips


      • If the exhaust valve guide bush bore diameter is more than 10.306 mm (0.4057 in.), machine the exhaust valve guide 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 exhaust valve guide bush.

      • If the exhaust valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.4077 in.), replace the cylinder head sub-assembly.

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

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

      CAUTION:

      Be sure to wear protective gloves.

    7. B006QVIC04
      *a Protrusion 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
      9.30 to 9.70 mm (0.3661 to 0.3819 in.)
    8. B006PLO

      Using a sharp 5.5 mm reamer, ream 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

    Note

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


    1. B006NKXC07
      *A for Bank 1
      *B for Bank 2
      *a 2.5 to 3.5 mm (0.0984 to 0.137 in.)

      Using a plastic hammer, tap in new ring pins to the cylinder head sub-assembly.

      Standard Protrusion Height
      2.5 to 3.5 mm (0.0984 to 0.138 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.

      B006LC4C02
      *a Bank 1 Rear Side *b Bank 1 Intake Side
      *c Bank 2 Intake Side *d Bank 1 Exhaust Side
      *e Bank 2 Exhaust Side *f Bank 2 Rear Side
      *g 20 mm (0.787 in.) *h 13 mm (0.512 in.)
      *i 35 mm (1.38 in.) *j 16 mm (0.630 in.)
      *k 9 mm (0.354 in.) *l 27 mm (1.06 in.)
      Torque:
      Bolt (A)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Bolt (B)
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  5. REPLACE STRAIGHT PIN

    Note

    If a straight pin is deformed, replace it.


    1. Using a plastic hammer, tap in new straight pins to the cylinder head sub-assembly as shown in the illustration.

      B006P86C10
      *A for Bank 1 *B for Bank 2
      *a 34 mm (1.34 in.) *b 17.5 to 19.5 mm (0.689 to 0.768 in.)
      Standard Protrusion Height
      17.5 to 19.5 mm (0.689 to 0.768 in.)