CYLINDER HEAD REPLACEMENT

PROCEDURE


  1. REPLACE INTAKE VALVE GUIDE BUSH


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

      CAUTION:

      Be sure to wear protective gloves.

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

    3. B003R5RN09

      Using SST and a hammer, tap out the intake valve guide bush from the cylinder head sub-assembly.

      SST
      09201-01055
      09950-70010   ( 09951-07100 )

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

      Standard Bush Bore Diameter
      Item Specified Condition
      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.)

      If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.406 in.), machine the intake valve guide bush bore diameter to between 10.335 and 10.356 mm (0.407 and 0.408 in.).

      If the intake valve guide 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. Select a new intake valve guide bush (STD or O/S 0.05).

      Intake Valve Guide Bush
      Bush Size Specified Condition
      Use STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
      Use O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.)

      Tech Tips

      Standard bush length: 43.0 to 44.0 mm (1.69 to 1.73 in.)

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

      CAUTION:

      Be sure to wear protective gloves.

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

    8. B003RDZC08
      *a Protrusion Height

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

      SST
      09201-01055
      09950-70010   ( 09951-07100 )
      Standard protrusion height
      9.8 to 10.2 mm (0.386 to 0.402 in.)
    9. B003PMF

      Using a sharp 5.5 mm reamer, ream the intake valve guide bush to obtain the standard specified clearance between the intake valve guide bush and intake 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 approximately 80 to 100°C (176 to 212°F).

      CAUTION:

      Be sure to wear protective gloves.

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

    3. B003MLVN06

      Using SST and a hammer, tap out the exhaust valve guide bush from the cylinder head sub-assembly.

      SST
      09201-01055
      09950-70010   ( 09951-07100 )

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

      Standard Bush Bore Diameter
      Item Specified Condition
      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.)

      If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.406 in.), machine the intake valve guide bush bore diameter to between 10.335 and 10.356 mm (0.407 and 0.408 in.).

      If the intake valve guide 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. Select a new exhaust valve guide bush (STD or O/S 0.05).

      Intake Valve Guide Bush
      Bush Size Specified Condition
      Use STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
      Use O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.)

      Tech Tips

      Standard bush length: 43.0 to 44.0 mm (1.69 to 1.73 in.)

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

      CAUTION:

      Be sure to wear protective gloves.

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

    8. B003RO9C08
      *a Protrusion Height

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

      SST
      09201-01055
      09950-70010   ( 09951-07100 )
      Standard protrusion height
      7.6 to 8.0 mm (0.299 to 0.315 in.)
    9. B003PVF

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

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

  3. REPLACE CAMSHAFT BEARING CAP SETTING RING PIN

    B003K06C03
    *a Height
    *b Width
    *c Protrusion Height

    Note

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


    1. Remove the ring pins.

    2. Using a plastic-faced hammer, tap in a new ring pin until the pin stops.

      Standard Ring Pin
      Item Height Width Protrusion Height
      Ring pin 7 mm (0.276 in.) 10 mm (0.394 in.) 2.5 to 3.8 mm (0.0984 to 0.150 in.)