CYLINDER HEAD REPLACEMENT

PROCEDURE


  1. REPLACE RING PIN

    Tech Tips

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


    1. A003NR0C01
      *a Top Side
      *b Width
      *c Height
      *d Protrusion Height

      Using a plastic hammer, tap in 2 new ring pins to the cylinder head sub-assembly.

      Standard Ring Pin
      Item Height Width Protrusion Height
      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.)

  2. REPLACE STUD BOLT

    Tech Tips

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


    1. Using E7 and E8 "TORX" socket wrenches, install the 9 stud bolts to the cylinder head sub-assembly.

      A003M6OC01
      *a Intake Manifold Side *b Exhaust Manifold Side
      *c Cylinder Head Rear Side *d 55 mm (2.17 in.)
      *e 13 mm (0.512 in.) *f 26 mm (1.02 in.)
      *g 32 mm (1.26 in.) *h 48 mm (1.89 in.)
      *i 12 mm (0.472 in.) *j 22 mm (0.866 in.)
      *k 42 mm (1.65 in.) - -
      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

  3. REPLACE INTAKE VALVE GUIDE BUSH


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

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

      CAUTION:

      Be sure to wear protective gloves.

    3. A003K0UC01
      *a Wooden Block

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
    4. A003MBQ

      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 (0.40492 to 0.40575 in.)
      New Guide Bush Selection Chart
      Bush Size Bush Bore Diameter
      STD 10.333 to 10.344 mm (0.40681 to 0.40724 in.)
      O/S 0.05 10.383 to 10.394 mm (0.40878 to 0.40921 in.)

      Tech Tips


      • If the intake valve guide bush bore diameter is more than 10.306 mm (0.40575 in.), machine the intake valve guide bush bore to a dimension of 10.335 to 10.356 mm (0.40689 to 0.40772 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 (0.40772 in.), replace the cylinder head sub-assembly.

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

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

      CAUTION:

      Be sure to wear protective gloves.

    7. A003KY4C01
      *a Protrusion Height
      *b Wooden Block

      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 (0.390 to 0.406 in.)
    8. A003LE2

      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.)

  4. REPLACE EXHAUST VALVE GUIDE BUSH


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

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

      CAUTION:

      Be sure to wear protective gloves.

    3. A003NUOC01
      *a Wooden Block

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
    4. A003LDJ

      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 (0.40492 to 0.40575 in.)
      New Guide Bush Selection Chart
      Bush Size Bush Bore Diameter
      STD 10.333 to 10.344 mm (0.40681 to 0.40724 in.)
      O/S 0.05 10.383 to 10.394 mm (0.40878 to 0.40921 in.)

      Tech Tips


      • If the exhaust valve guide bush bore diameter is more than 10.306 mm (0.40575 in.), machine the exhaust valve guide bush bore to a dimension of 10.335 to 10.356 mm (0.40689 to 0.40772 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 (0.40772 in.), replace the cylinder head sub-assembly.

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

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

      CAUTION:

      Be sure to wear protective gloves.

    7. A003LUCC02
      *a Protrusion Height
      *b Wooden Block

      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 (0.439 to 0.455 in.)
    8. A003ORW

      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.)