1. CLEAN TOP OF PISTONS AND TOP OF BLOCK
(a) Turn the crankshaft and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top.
(b) Remove all the gasket material from the top of the cylinder block.
(c) Using compressed air, blow carbon and oil from the bolt holes.
WARNING: Protect your eyes when using high pressure air.
2. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all gasket material from the head and manifold surfaces.
CAUTION: Be careful not to scratch the surfaces.
3. CLEAN COMBUSTION CHAMBER
Using a wire brush, remove all the carbon from the combustion chambers.
CAUTION: Be careful not to scratch the head gasket contact surfaces.
4. CLEAN VALVE GUIDE BUSHINGS
Using a valve guide brush and solvent, clean all the valve guide bushings.
5. CLEAN CYLINDER HEAD
Using a soft brush and solvent, throughly clean the head.
CAUTION: Do not clean the head in a hot tank as this would seriously damage it.
6. INSPECT CYLINDER HEAD FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and manifold for warpage.
Maximum surface warpage:
Cylinder block side 0.05 mm (0.0020 in.) Intake manifold side 0.05 mm (0.0020 in.) Exhaust manifold side 0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the cylinder head.
7. INSPECT CYLINDER HEAD FOR CRACKS
Using a dye penetrant, check the combustion chamber, intake and exhaust ports, head surface and the top of the head for cracks.
If a crack is found, replace the head.
8. CLEAN VALVES
(a) Using a gasket scraper, chip any carbon from the valve.
(b) Using a wire brush, throughly clean the valve.
9. INSPECT VALVE STEM AND GUIDE BUSHINGS
(a) Using a caliper gauge, measure the inside diameter of the guide bushing.
Bushing inside diameter:
(b) Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter
(c) Subtract the valve stem measurement from the valve guide bushing measurement.
Standard stem oil clearance:
Maximum stem oil clearance:
Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.)
If the clearance more than maximum, replace the valve and guide bushing.
10. IF NECESSARY, REPLACE VALVE GUIDE BUSHING
(a) Insert an old valve wrapped with tape into the valve guide bushing and break off the valve guide bushing by hitting it with a hammer.
CAUTION: Be careful not to damage the liter port.
(b) Gradually heat the cylinder head to 80 - 100°C (176 - 212°F).
(c) Using SST and a hammer, drive out the valve guide bushing.
(d) Using a caliper gauge, measure the valve guide bore of the cylinder head.
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