RM35X0E _51 Engine / Hybrid System _078603 7GR-FKS ENGINE MECHANICAL _0381345 CYLINDER HEAD A

7GR-FKS ENGINE MECHANICAL  CYLINDER HEAD  REPLACEMENT  


PROCEDURE

Hide 11122C 1.REPLACE INTAKE VALVE GUIDE BUSH

a.

Heat the cylinder head to 80 to 100°C (176 to 212°F).


b.

Place the cylinder head on wooden blocks.

CAUTION:

Be sure to wear protective gloves.



c.
A410038N01
1.615,0.771 1.948,0.188 1.948,0.188 1.792,1.302 true 2,0.052 2.458,0.25 0.458,0.198 10 false SST

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

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


d.

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

Standard cylinder bore diameter:

10.285 to 10.306 mm (0.4049 to 0.4057 in.)


Select a New Guide Bush (STD or O/S 0.05):
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 bush bore diameter of the cylinder head is more than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 valve guide bush.

If the bush bore diameter of the cylinder head is more than 10.356 mm (0.4077 in.), replace the cylinder head.


e.

Heat the cylinder head to 80 to 100°C (176 to 212°F).


f.

Place the cylinder head on wooden blocks.

CAUTION:

Be sure to wear protective gloves.



g.
A410041C01
1.781,1.281 1.979,0.208 1.979,0.208 1.615,0.75 true 2.896,0.625 3.208,0.823 0.313,0.198 10 false *a 2,0.073 2.458,0.271 0.458,0.198 10 false SST
*a Protrusion Height


Using SST, tap in new intake valve guide bushes to the specified protrusion height.

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

Standard protrusion height:

9.10 to 9.90 mm (0.358 to 0.390 in.)



h.
A410042

Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.

Standard oil clearance:

0.025 to 0.060 mm (0.000984 to 0.00236 in.)



Hide 11126C 2.REPLACE EXHAUST VALVE GUIDE BUSH

a.

Heat the cylinder head to 80 to 100°C (176 to 212°F).


b.

Place the cylinder head on wooden blocks.

CAUTION:

Be sure to wear protective gloves.



c.
A278408N08
2.082,0.656 1.902,0.164 1.902,0.164 1.793,0.164 false 2.018,1.139 1.902,0.164 false 1.452,0.086 1.754,0.263 0.302,0.177 10 SST

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

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


d.

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

Standard cylinder bore diameter:

10.285 to 10.306 mm (0.4049 to 0.4057 in.)


Select a New Guide Bush (STD or O/S 0.05):
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 bush bore diameter of the cylinder head is more than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 valve guide bush.

If the bush bore diameter of the cylinder head is more than 10.356 mm (0.4077 in.), replace the cylinder head.


e.

Heat the cylinder head to 80 to 100°C (176 to 212°F).


f.

Place the cylinder head on wooden blocks.

CAUTION:

Be sure to wear protective gloves.



g.
A410043C01
2.146,1.104 2.948,1.198 2.948,1.198 2.26,0.635 true 0.354,1.146 0.667,1.302 0.313,0.156 10 false *a 3.042,1.146 3.344,1.344 0.302,0.198 10 false SST
*a Protrusion Height


Using SST, tap in new exhaust valve guide bushes to the specified protrusion height.

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

Standard protrusion height:

9.10 to 9.90 mm (0.358 to 0.390 in.)



h.
A410044

Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.

Standard oil clearance:

0.030 to 0.065 mm (0.00118 to 0.00256 in.)



Hide 3.REPLACE RING PIN

NOTICE:
A410048C02
0.104,0.083 0.417,0.24 0.313,0.156 10 false *A 0.104,2.073 0.417,2.229 0.313,0.156 10 false *B 2.375,4 2.688,4.156 0.313,0.156 10 false *a
*A for Bank 1
*B for Bank 2
*a Protrusion Height


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


a.

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

Standard protrusion height:

2.5 to 3.5 mm (0.0984 to 0.138 in.)



Hide 11114A 4.REPLACE STRAIGHT PIN

NOTICE:

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


a.

Using a plastic-faced hammer, tap in new straight pins as shown in the illustration.

A410049C02
0.271,0.135 0.583,0.313 0.313,0.177 10 false *A 3.26,0.146 3.563,0.344 0.302,0.198 10 false *B 5.833,0.833 6.115,1.031 0.281,0.198 10 false *b 6.823,0.635 7.104,0.823 0.281,0.188 10 false *a
*A for Bank 1 *B for Bank 2
*a Protrusion Height *b 34 mm (1.34 in.)


Standard protrusion height:

17.5 to 19.5 mm (0.689 to 0.768 in.)