8ZR-FXE ENGINE MECHANICAL  CYLINDER HEAD  REPLACEMENT  

0.302,0.063 0.615,0.219 0.313,0.156 10 false *a 0.844,2.438 1.156,2.594 0.313,0.156 10 false *b 1.333,3 1.646,3.156 0.313,0.156 10 false *c 1.604,3.708 1.917,3.865 0.313,0.156 10 false *d

*a	Top Side
*b	Width
*c	Height
*d	Protrusion Height

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

Standard Ring Pin:

Item	Height	Width	Protrusion
Ring pin	11.7 to 12.3 mm (0.461 to 0.484 in.)	12.0 mm (0.472 in.)	6.5 to 7.5 mm (0.256 to 0.295 in.)

Using E7 and E8 "TORX" socket wrenches, install the 9 stud bolts to the cylinder head sub-assembly.

0.344,0.125 0.656,0.281 0.313,0.156 10 false *a 4.073,0.104 4.385,0.26 0.313,0.156 10 false *b 2.625,1.948 2.938,2.104 0.313,0.156 10 false *c 4.271,4.573 4.583,4.729 0.313,0.156 10 false *d 3.521,5 3.833,5.156 0.313,0.156 10 false *e 3.542,4.406 3.854,4.563 0.313,0.156 10 false *f 1.135,4.375 1.448,4.531 0.313,0.156 10 false *g 1.833,4.604 2.146,4.76 0.313,0.156 10 false *h 1.125,5 1.438,5.156 0.313,0.156 10 false *e 0.635,3.823 0.948,3.979 0.313,0.156 10 false *a 5.156,4 5.469,4.156 0.313,0.156 10 false *b 3.031,3.792 3.344,3.948 0.313,0.156 10 false *c 5.635,4.979 5.948,5.135 0.313,0.156 10 false *e 5.646,4.583 5.958,4.74 0.313,0.156 10 false *i 6.375,4.698 6.688,4.854 0.313,0.156 10 false *j

*a	Intake Manifold Side	*b	Exhaust Manifold Side
*c	Cylinder Head Rear Side	*d	55 mm (2.17 in.)
*e	13 mm (0.512 in.)	*f	26 mm (1.02 in.)
*g	24 mm (0.945 in.)	*h	49.5 mm (1.95 in.)
*i	20 mm (0.787 in.)	*j	42 mm (1.65 in.)

Torque:

9.5 N*m (97 kgf*cm, 84 in.*lbf)

0.219,1.906 0.604,1.906 false 1.146,1.125 0.698,0.219 0.698,0.219 1.24,0.521 true 0.021,1.844 0.333,2 0.313,0.156 10 false *a 0.396,0.104 0.854,0.302 0.458,0.198 10 false SST

*a	Wooden Block

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

SST

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

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:

10.285 to 10.306 mm (0.40492 to 0.40575 in.)

New Guide Bush Selection Chart:

Bush Size	Bush Bore Diameter
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.)

HINT:

·

If the intake valve guide bush bore diameter is more than 10.306 mm (0.40575 in.), machine the intake valve guide bush bore to a dimension of 10.335 to 10.356 mm (0.40689 to 0.40772 in.) to install an O/S 0.05 intake valve guide bush.

·

If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.40772 in.), replace the cylinder head sub-assembly.

0.396,1.948 0.688,1.948 false 1.125,1.135 0.438,0.344 0.438,0.344 1.24,0.563 true 3.156,0.969 3.427,1.208 0.271,0.24 10 false *a 0.188,1.865 0.5,2.021 0.313,0.156 10 false *b 0.156,0.25 0.615,0.448 0.458,0.198 10 false SST

*a	Protrusion Height
*b	Wooden Block

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

SST

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

Standard Protrusion Height:

9.9 to 10.3 mm (0.390 to 0.406 in.)

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

Standard Oil Clearance:

0.025 to 0.060 mm (0.000984 to 0.00236 in.)

1.448,2.031 1.885,2.031 false 2.177,1.208 1.75,0.677 1.75,0.677 1.917,0.656 true 1.26,1.958 1.573,2.115 0.313,0.156 10 false *a 1.417,0.594 1.875,0.792 0.458,0.198 10 false SST

*a	Wooden Block

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

SST

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

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:

10.285 to 10.306 mm (0.40492 to 0.40575 in.)

New Guide Bush Selection Chart:

Bush Size	Bush Bore Diameter
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.)

HINT:

·

If the exhaust valve guide bush bore diameter is more than 10.306 mm (0.40575 in.), machine the exhaust valve guide bush bore to a dimension of 10.335 to 10.356 mm (0.40689 to 0.40772 in.) to install an O/S 0.05 exhaust valve guide bush.

·

If the exhaust valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.40772 in.), replace the cylinder head sub-assembly.

1.813,1.917 2.125,1.917 false 2.344,1.063 1.781,0.646 1.781,0.646 2.052,0.542 true 0.99,0.938 1.302,1.094 0.313,0.156 10 false *a 1.615,1.854 1.927,2.01 0.313,0.156 10 false *b 1.51,0.583 1.969,0.781 0.458,0.198 10 false SST

*a	Protrusion Height
*b	Wooden Block

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

SST

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

Standard Protrusion Height:

11.15 to 11.55 mm (0.439 to 0.455 in.)

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

Standard Oil Clearance:

0.030 to 0.065 mm (0.00118 to 0.00256 in.)