CYLINDER HEAD REPLACEMENT

PROCEDURE


  1. REPLACE NO. 2 INTAKE VALVE GUIDE BUSH


    1. Place the cylinder block on wooden blocks with the combustion chamber side facing upward.

    2. A004K1UE01

      Using SST and a hammer, tap out the No. 2 intake valve guide bush.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )

      Note


      • Place wooden blocks wrapped in a cloth under the cylinder head and stabilize the cylinder head during servicing.

      • Use special care not to damage the cylinder head.

    3. Before installing the No. 2 intake valve guide bush, make sure that neither scratches nor damages exist on the inner surface of cylinder head valve guide bush holes.

    4. A004I2KE03
      Text in Illustration
      *a Reference line

      Draw a reference line 7.6 mm (0.299 in.) below from the top face on a new No. 2 intake valve guide bush using a marker.

      Tech Tips

      Reference line is used as a guide when tapping-in the No. 2 intake valve guide bush.

    5. Place the cylinder block on wooden blocks with the combustion chamber side facing downward.

    6. Apply enough engine oil to the No. 2 intake valve guide bush, and set it on the cylinder head.

    7. A004HODE01

      Using SST and a hammer, tap in the No. 2 intake valve guide bush to the reference line.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )

      Note


      • Place wooden blocks wrapped in a cloth under the cylinder head and stabilize the cylinder head during servicing.

      • Use special care not to damage the cylinder head.

    8. A004HRVE03
      Text in Illustration
      *a Protrusion height

      While measuring the No. 2 intake valve guide bush protrusion amount using a vernier caliper, tap in the No. 2 intake valve guide bush so that its height is within the standard.

      Standard protrusion height
      11.4 to 11.8 mm (0.449 to 0.466 in.)

      Note


      • Place wooden blocks wrapped in a cloth under the cylinder head and stabilize the cylinder head during servicing.

      • Use special care not to damage the cylinder head.

      Tech Tips

      Use multiple small repetitions of tap-in and measurement in order not to excessively tap in the No. 2 intake valve guide bush.

    9. Place the cylinder block on wooden blocks with the combustion chamber side facing upward.

      Note


      • Place wooden blocks wrapped in a cloth under the cylinder head and stabilize the cylinder head during servicing.

      • Use special care not to damage the cylinder head.

    10. A004I6X

      Using a reamer, ream the No. 2 intake valve guide bush to obtain the standard clearance between the No. 2 intake valve guide bush and valve stem.

      Standard inside diameter
      5.500 to 5.512 mm (0.21654 to 0.21701 in.) at 20°C (68°F)

      Note

      While gradually widening the reamer diameter, ream the No. 2 intake valve guide bush uniformly so that the oil clearance is within the standard.

      Tech Tips


      • Apply engine oil to the reamer when reaming.

      • If the inner surface of No. 2 intake valve guide bush is damaged, slightly grind the edge of the reamer with 400-grit sandpaper.

      • If the inner surface of No. 2 intake valve guide bush becomes lustrous and the reamer does not chip, use a new reamer or correct the reamer.

    11. After reaming, remove chips and clean the No. 2 intake valve guide bush.

    12. Measure the inside diameter of the No. 2 intake valve guide bush and confirm the oil clearance.

    13. Check the contact condition between the valve and valve seat.

  2. REPLACE NO. 2 EXHAUST VALVE GUIDE BUSH


    1. Place the cylinder block on wooden blocks with the combustion chamber side facing upward.

    2. A004JATE01

      Using SST and a hammer, tap out the No. 2 exhaust valve guide bush.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )

      Note


      • Place wooden blocks wrapped in a cloth under the cylinder head and stabilize the cylinder head during servicing.

      • Use special care not to damage the cylinder head.

    3. Before installing the No. 2 exhaust valve guide bush, make sure that neither scratches nor damages exist on the inner surface of cylinder head valve guide bush holes.

    4. A004KUJE05
      Text in Illustration
      *a Reference line

      Draw a reference line 7.6 mm (0.299 in.) below from the top face on a new No. 2 exhaust valve guide bush using a marker.

      Tech Tips

      Reference line is used as a guide when tapping-in the No. 2 exhaust valve guide bush.

    5. Place the cylinder block on wooden blocks with the combustion chamber side facing downward.

    6. Apply enough engine oil to the No. 2 exhaust valve guide bush, and set it on the cylinder head.

    7. A004HODE01

      Using SST and a hammer, tap in the No. 2 exhaust valve guide bush to the reference line.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )

      Note


      • Place wooden blocks wrapped in a cloth under the cylinder head and stabilize the cylinder head during servicing.

      • Use special care not to damage the cylinder head.

    8. A004HRVE03
      Text in Illustration
      *a Protrusion height

      While measuring the No. 2 exhaust valve guide bush protrusion amount using a vernier caliper, tap in the No. 2 exhaust valve guide bush so that its height is within the standard.

      Standard protrusion height
      11.4 to 11.8 mm (0.449 to 0.466 in.)

      Note


      • Place wooden blocks wrapped in a cloth under the cylinder head and stabilize the cylinder head during servicing.

      • Use special care not to damage the cylinder head.

      Tech Tips

      Use multiple small repetitions of tap-in and measurement in order not to excessively tap in the No. 2 exhaust valve guide bush.

    9. Place the cylinder block on wooden blocks with the combustion chamber side facing upward.

      Note


      • Place wooden blocks wrapped in a cloth under the cylinder head and stabilize the cylinder head during servicing.

      • Use special care not to damage the cylinder head.

    10. A004I6X

      Using a reamer, ream the No. 2 exhaust valve guide bush to obtain the standard clearance between the No. 2 exhaust valve guide bush and valve stem.

      Standard inside diameter
      5.500 to 5.512 mm (0.21654 to 0.21701 in.) at 20°C (68°F)

      Note

      While gradually widening the reamer diameter, ream the No. 2 exhaust valve guide bush uniformly so that the oil clearance is within the standard.

      Tech Tips


      • Apply engine oil to the reamer when reaming.

      • If the inner surface of No. 2 exhaust valve guide bush is damaged, slightly grind the edge of the reamer with 400-grit sandpaper.

      • If the inner surface of No. 2 exhaust valve guide bush becomes lustrous and the reamer does not chip, use a new reamer or correct the reamer.

    11. After reaming, remove chips and clean the No. 2 exhaust valve guide bush.

    12. Measure the inside diameter of the No. 2 exhaust valve guide bush and confirm the oil clearance.

    13. Check the contact condition between the valve and valve seat.