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CYLINDER HEAD REPLACEMENT

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PROCEDURE


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    REPLACE INTAKE VALVE GUIDE BUSH


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

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

    3. A0007XAE10

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

      09201-01055
      09950-70010 09951-07100
    4. A0007A4

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

      Standard bush bore diameter
      10.285 to 10.306 mm (0.405 to 0.406 in.)

      If the intake valve guide bush bore diameter of the cylinder head sub-assembly is 10.356 mm (0.408 in.) or more, replace the cylinder head sub-assembly.

    5. Select a new intake valve guide bush (STD or O/S 0.05), and measure its diameter.

    6. Machine the intake valve guide bush bore of the cylinder head sub-assembly to the diameter of the selected intake valve guide bush.

      Intake Valve Guide Bush Bore Diameter
      Bush Size Specified Condition
      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.)
      Standard bush length
      41.3 to 41.7 mm (1.626 to 1.642 in.)

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

    8. A000982E11

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

      09201-10000 09201-01050
      09950-70010 09951-07100
      Standard protrusion height
      14.8 to 15.2 mm (0.583 to 0.598 in.)
      Table 1. Text in Illustration
      *a Height
    9. A0008MZ

      Using a sharp 5.5 mm reamer, ream the intake valve guide bush to obtain the standard oil 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.)
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    REPLACE EXHAUST VALVE GUIDE BUSH


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

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

    3. A0005JKE05

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

      09201-01055
      09950-70010 09951-07100
    4. A0008GJ

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

      Standard bush bore diameter
      10.285 to 10.306 mm (0.405 to 0.406 in.)

      If the exhaust valve guide bush bore diameter of the cylinder head sub-assembly is 10.356 mm (0.408 in.) or more, replace the cylinder head sub-assembly.

    5. Select a new exhaust valve guide bush (STD or O/S 0.05), and measure its diameter.

    6. Machine the exhaust valve guide bush bore of the cylinder head sub-assembly to the diameter of the selected exhaust valve guide bush.

      Exhaust Valve Guide Bush Bore Diameter
      Bush Size Specified Condition
      STD 10.333 to 10.344 mm (0.4068 in 0.4072 in.)
      O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.)
      Standard bush length
      46.8 to 47.2 mm (1.843 to 1.858 in.)

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

    8. A00096LE01

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

      09201-10000 09201-01050
      09950-70010 09951-07100
      Standard protrusion height
      14.2 to 14.6 mm (0.559 to 0.575 in.)
      Table 2. Text in Illustration
      *a Height
    9. A0007G7

      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.)
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    REPLACE RING PIN

    Note:

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


    1. Remove the 2 ring pins.

    2. A00082OE10
      Table 3.
      *1 6.5 to 7.5 mm

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

      Standard protrusion height
      6.5 to 7.5 mm (0.256 to 0.295 in.)