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Cylinder Head: Replacement

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.
  1. REPLACE INTAKE VALVE GUIDE BUSH 
    1. Heat the cylinder head sub-assembly to approximately 80 to 100°C (176 to 212°F)
    2. Place the cylinder head sub-assembly on wooden blocks.
    3. Using SST and a hammer, tap out the intake valve guide bush

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

      Fig 1: Tapping Out Intake Valve Guide Bush
      G05749791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a caliper gauge, measure the bush bore diameter of the cylinder head side.

      Standard cylinder bore diameter: 

      10.285 to 10.306 mm (0.405 to 0.406 in.) 

      If the bush bore diameter of the cylinder head sub-assembly is between 10.285 and 10.306 mm (0.405 and 0.406 in.), proceed to the next step. If the bush bore diameter of the cylinder head sub-assembly is 10.356 mm (0.408 in.) or more, replace the cylinder head sub-assembly

      Fig 2: Measuring Bush Bore Diameter Of Cylinder Head Side
      G04943477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Select a new intake valve guide bush (STD or O/S 0.05), and measure its diameter
    6. Machine the bush bore diameter of the cylinder head sub-assembly to the diameter of the selected intake valve guide bush.

      Bush Bore Diameter 

      BUSH BORE DIAMETER SPECIFICATION

      Bush Size Specified Condition
      STD 10 285 to 10.306 mm (0 405 to 0.406 in.)
      O/S 0.05 10 335 to 10.356 mm (0.407 to 0.408 in.)
    7. Heat the cylinder head sub-assembly to approximately 80 to 100°C (176 to 212°F)
    8. 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: 

      14.3 to 14.7 mm (0.563 to 0.579 in.) 

      Fig 3: Installing Intake Valve Guide Bush
      G05749793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using a sharp 5.5 mm reamer, ream the intake valve guide bush to obtain the specified clearance between the intake valve guide bush and valve stem
  2. REPLACE EXHAUST VALVE GUIDE BUSH 
    1. Heat the cylinder head sub-assembly to approximately 80 to 100°C (176 to 212°F)
    2. Place the cylinder head sub-assembly on wooden blocks
      Fig 4: Reaming Intake Valve Guide Bush
      G05749794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a hammer, tap out the exhaust valve guide bush.

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

      Fig 5: Removing Exhaust Valve Guide Bush
      G05749795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a caliper gauge, measure the bush bore diameter of the cylinder head side

      Standard cylinder bore diameter: 

      10.285 to 10.306 mm (0.405 to 0.406 in.) 

      • If the bush diameter of the cylinder head sub-assembly is between 10.285 and 10.306 mm (0.405 and 0.406 in), proceed to the next step.
      • If the bush bore diameter of the cylinder head sub-assembly is 10.356 mm (0.408 in) or more, replace the cylinder head sub-assembly
      Fig 6: Measuring Bush Bore Diameter Of Cylinder Head Side
      G04943481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Select a new exhaust valve guide bush (STD or O/S 0.05), and measure its diameter
    6. Machine the bush bore diameter of the cylinder head side to the diameter of the selected exhaust valve guide bush.

      Bush Bore Diameter 

      BUSH BORE DIAMETER SPECIFICATION

      Bush Size Specified Condition
      STD 10.285 to 10 306 mm (0 405 to 0 406 in.)
      O/S 0.05 10 335 to 10 356 mm (0 407 to 0.408 in.)
    7. Heat the cylinder head sub-assembly to approximately 80 to 100°C (176 to 212°F)
    8. 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: 

      14.3 to 14.7 mm (0.563 to 0.579 in.) 

      Fig 7: Installing Exhaust Valve Guide Bush
      G05749797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using a sharp 5.5 mm reamer, ream the exhaust valve guide bush to obtain the specified clearance between the exhaust valve guide bush and exhaust valve stem
  3. REPLACE STRAIGHT PIN 
    NOTE: It is not necessary to remove the straight pins unless they are being replaced.
    1. Remove the straight pins.
      Fig 8: Reaming Exhaust Valve Guide Bush
      G05749798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic-faced hammer, tap in new straight pins until they stop
      Fig 9: Identifying Straight Pin Protrusion
      G05749799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard protrusion: 

      8.0 to 10.0 mm (0.315 to 0.394 in.) 

  4. REPLACE STUD BOLT 
    NOTE: If a stud bolt is deformed or the threads are damaged, replace it.
    1. Remove the stud bolts
    2. Using E6 and E8 "TORX" socket wrenches, install the stud bolts.
      Fig 10: Identifying Stud Bolts Dimension
      G05749800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: Bolt A, B, C and D 

      9.0 N*m (92 kgf*cm, 80 in.*lbf) 

      Bolt E 

      5.0 N*m (51 kgf*cm, 44 in.*lbf) 

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