using bushing driver and hammer.
(2) Use a flat mill file to file sleeve flush with
top of cylinder head. Do not damage head
diameter of sleeve, clean all cuttings and
filings from water passages.
(3) If proper sleeve is not available, heavy wall
copper tubing may be used. Tubing must
provide 0.002 to 0.005 inch (0.05 to 0.13
mm) press fit. Overall length should be
approximately 1/2 inch (12.70 mm); inside
diameter must be 7/16 inch (11.11 mm) to
allow proper water flow.
(4) Resurface head if it has been scratched,
etched, or worn unevenly at point of contact
with gasket sealing areas. Check erosion
around water holes which could cause
failure of head gasket to seal. If eroded,
install bushings before resurfacing head.
(5) Remove 0.005 to 0.006 inch (0.13 to 0.15
mm) material at one time and no more than
0.030 inch (0.76 mm) total. Refer to
tabulated data in Chapter 1.
Waviness on mounting surface must not
exceed 0.0004 inch (0.010 mm) in depth
and distance between high and low
points must not be closer than 1.00 inch
(25.4 mm). Surface not to deviate from a
true plane more than 0.0003 inch (0.008
mm) within 0.250 inch (6.35 mm) of any
opening and entire surface must not
deviate from true plane more than 0.004
inch (0.10 mm) T.I.R.
(6) Rework valve seat insert counterbore by
removing amount of stock equal to that
removed during head resurfacing operation.
(7) Sand surface of cylinder head with an
orbital sander. Do not use a disc sander.
Do not allow the sander to tilt or rock, since
this may result in rounding of the machined
(8) After resurfacing check head height, use
micrometer or vernier depth gauge. Do not
remove more than indicated as worn limit.
See tabulated data in Chapter 1.
(9) Check exhaust ports for flatness after head
has been resurfaced. Ports should not be
out of plane more than 0.003 inch (0.08
(10) Install new injector sleeves to maintain
correct injector tip protrusion.
(11) Check overall height of assembled valve
springs to see if it is necessary to install
spacers (1/16 inch (1.59 mm) maximum)
under springs to obtain correct assembled
Only 1/32 inch (0.79 mm) spacer can be
used if head has not been resurfaced.
(12) Drive out worn guides from underside of
(13) Install new guides with arbor press and
(14) If proper valve guide mandrels are not
available, press guides into head to obtain
1.270 to 1.280 inch (32.26 to 32.51 mm)
protrusion above head surface.
(a) Ream valve guide from bottom side of
cylinder head using a drill press and
floating tool holder.
Use lubricating oil or soluble oil and
water solution for good finish.
(b) Ream valve guides with reamer to
(11.493 to 11.511 mm).