CYLINDER HEAD(w/ Glow Plug Controller) 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).

      CAUTION:

      Make sure not to burn yourself.

    2. A068054

      Using SST and a hammer, tap out the intake valve guide bush to the combustion chamber side.

      09201-10000

      09201-01050

      09950-70010

    3. A300218

      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

      10.985 to 11.006 mm (0.4325 to 0.4333 in.)

      Tip:

      • If the intake valve guide bush bore diameter is as specified, install a standard intake valve guide bush.

      • If the intake valve guide bush bore diameter is not as specified, correct it to 11.035 to 11.056 mm (0.4344 to 0.4353 in.) and install the oversize intake valve guide bush.

        Bush Size

        Specified Condition

        STD

        10.985 to 11.006 mm (0.4325 to 0.4333 in.)

        O/S 0.05

        11.035 to 11.056 mm (0.4344 to 0.4353 in.)

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

      CAUTION:

      Make sure not to burn yourself.

    5. A286912E01

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

      09201-10000

      09201-01050

      09950-70010

      Standard Protrusion Height

      15.9 to 16.7 mm (0.626 to 0.657 in.)

    6. A210198

      Using a reamer, ream the inside of the intake valve guide bush to the specified oil 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 between 80 and 100°C (176 and 212°F).

      CAUTION:

      Make sure not to burn yourself.

    2. A286913N02

      Using SST and a hammer, tap out the exhaust valve guide bush to the combustion chamber side.

      09201-10000

      09201-01050

      09950-70010

    3. E270274

      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

      10.985 to 11.006 mm (0.4325 to 0.4333 in.)

      Tip:

      • If the exhaust valve guide bush bore diameter is as specified, install a standard exhaust valve guide bush.

      • If the exhaust valve guide bush bore diameter is not as specified, correct it to 11.035 to 11.056 mm (0.4345 to 0.4353 in.) and install the oversize exhaust valve guide bush.

        Bush Size

        Specified Condition

        STD

        10.985 to 11.006 mm (0.4325 to 0.4333 in.)

        O/S 0.05

        11.035 to 11.056 mm (0.4344 to 0.4353 in.)

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

      CAUTION:

      Make sure not to burn yourself.

    5. A286914E01

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

      09201-10000

      09201-01050

      09950-70010

      Standard Protrusion Height

      15.9 to 16.7 mm (0.626 to 0.657 in.)

    6. A210199

      Using a reamer, ream the inside of the exhaust valve guide bush to the specified oil 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 RING PIN

    Note:

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

    1. A340415

      Remove the 4 ring pins indicated in the illustration.

    2. A340416C01

      *a

      Protrusion Height

      Using a plastic hammer, tap in 4 new ring pins to the specified protrusion height.

      Ring Pin

      Protrusion Height

      (A)

      3.5 mm (0.138 in.)

      (B)

      4.0 to 5.0 mm (0.157 to 0.197 in.)

  4. REPLACE STRAIGHT PIN

    Note:

    It is not necessary to remove the straight pin unless they are being replaced.

    1. A198444

      Remove the straight pin indicated in the illustration.

    2. A349650C01

      *a

      Protrusion Height

      Using a plastic hammer, tap in a new straight pin to the specified protrusion height.

      Standard Protrusion Height

      18.5 to 19.5 mm (0.728 to 0.768 in.)

  5. REPLACE STUD BOLT

    1. Using an E6, E8 and E10 "TORX" socket wrenches, remove the 16 stud bolts.

      A340417C01

      *a

      Front Side

      *b

      Exhaust Manifold Side

      *c

      Rear Side

      *d

      Intake Manifold Side

      *e

      Upper Side

      -

      -

    2. Using an E6, E8 and E10 "TORX" socket wrench, install the 16 stud bolts.

      A340418C01

      *a

      Front Side

      *b

      Exhaust Manifold Side

      *c

      Rear Side

      *d

      Intake Manifold Side

      *e

      Upper Side

      *f

      42.0 mm (1.65 in.)

      *g

      27.0 mm (1.06 in.)

      *h

      13.0 mm (0.512 in.)

      *i

      48.5 mm (1.91 in.)

      *j

      31.5 mm (1.24 in.)

      *k

      15.0 mm (0.591 in.)

      *l

      39.0 mm (1.54 in.)

      *m

      26.0 mm (1.02 in.)

      *n

      9.0 mm (0.354 in.)

      *o

      42.0 mm (1.65 in.)

      *p

      17.0 mm (0.669 in.)

      *q

      12.0 mm (0.472 in.)

      -

      -

      Stud Bolt (A)

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      Stud Bolt (B)

      15 N*m

      153 kgf*cm

      11 ft.*lbf

      Stud Bolt (C), (D)

      5.0 N*m

      51 kgf*cm

      44 in.*lbf