TM5-6115-593-34 NAVFAC P-8-631-34 TO-35C2-3-463-2 using bushing driver and hammer. (2)   Use  a  flat  mill  file  to  file  sleeve  flush  with top of cylinder head.  Do not damage head surface. Remove burrs from inside 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. NOTE 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 edges. (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 mm). (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 height. CAUTION 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 cylinder head. (13)   Install   new   guides   with   arbor   press   and mandrel. (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. NOTE Use   lubricating   oil   or   soluble   oil   and water solution for good finish. (b)   Ream    valve    guides    with    reamer    to dimensions 0.4525 to 0.4532 inch (11.493 to 11.511 mm). 13-83