CYLINDER HEAD REPLACEMENT

PROCEDURE


  1. 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:

      As the cylinder head sub-assembly is very hot, make sure to wear protective gloves when servicing.

    3. A01ODN7N02

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

      SST
      09201-01055
      09950-70010   ( 09951-07100 )
    4. A01OBYM

      Using a caliper gauge, measure the 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 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), and measure its diameter.

      Bush Bore Diameter
      Bush Size Specified Condition
      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.)

      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 bush bore to a dimension of 10.335 to 10.356 mm (0.407 to 0.408 in.) to install an O/S 0.05 intake valve guide bush.

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

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

    8. A01OBWRC02
      *a Height

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Standard Protrusion Height
      14.85 to 15.10 mm (0.585 to 0.594 in.)

      CAUTION:

      As the cylinder head sub-assembly is very hot, make sure to wear protective gloves when servicing.

    9. A01OBCK

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

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

      CAUTION:

      As the cylinder head sub-assembly is very hot, make sure to wear protective gloves when servicing.

    3. A01OCBDN02

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

      SST
      09201-01055
      09950-70010   ( 09951-07100 )
    4. A01OAIU

      Using a caliper gauge, measure the 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 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), and measure its diameter.

      Bush Bore Diameter
      Bush Size Specified Condition
      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.)

      If the exhaust valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.406 in.), machine the bush bore to a dimension of 10.335 to 10.356 mm (0.407 to 0.408 in.) to install an O/S 0.05 exhaust valve guide bush.

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

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

    8. A01ODL7C02
      *a Height

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Standard Protrusion Height
      14.25 to 14.50 mm (0.561 to 0.571 in.)

      CAUTION:

      As the cylinder head sub-assembly is very hot, make sure to wear protective gloves when servicing.

    9. A01OA3O

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

      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. Remove the 2 ring pins.

    2. A01ODIEC01
      *a Protrusion Height

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

      Standard Protrusion Height
      6.5 to 7.5 mm (0.256 to 0.295 in.)