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Replacement [08/2015 - ]: Procedure

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  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: 09201-01055 
      • SST: 09950-70010 
        1. 09951-07100
      GTY499355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a caliper gauge, measure the bush bore diameter of the cylinder head sub-assembly.

      Standard bush 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 to 10.306 mm (0.405 to 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.

    5. Heat the cylinder head sub-assembly to approximately 80 to 100°C (176 to 212°F).
    6. Using SST and a hammer, tap in a new intake valve guide bush to the standard protrusion height.
      • SST: 09201-10000 
        1. 09201-01050
      • SST: 09950-70010 
        1. 09951-07100
      GTY507303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height

      Standard protrusion height

      14.85 to 15.10 mm (0.585 to 0.594 in.)

    7. Using a sharp 5.5 mm reamer, ream the intake valve guide bush to obtain the standard oil clearance between the intake valve guide bush and intake valve stem.
      GTY518542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard oil clearance

      0.025 to 0.060 mm (0.000984 to 0.00236 in.)

  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.
    3. Using SST and a hammer, tap out the exhaust valve guide bush.
      • SST: 09201-01055 
      • SST: 09950-70010 
        1. 09951-07100
      GTY511752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a caliper gauge, measure the bush bore diameter of the cylinder head sub-assembly.

      Standard bush 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 to 10.306 mm (0.405 to 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.

    5. Heat the cylinder head sub-assembly to approximately 80 to 100°C (176 to 212°F).
    6. Using SST and a hammer, tap in a new exhaust valve guide bush to the standard protrusion height.
      • SST: 09201-10000 
        1. 09201-01050
      • SST: 09950-70010 
        1. 09951-07100
      GTY497960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height

      Standard protrusion height

      19.25 to 19.50 mm (0.758 to 0.768 in.)

    7. Using a sharp 5.5 mm reamer, ream the exhaust valve guide bush to obtain the standard oil clearance between the exhaust valve guide bush and exhaust valve stem.
      GTY502228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard oil clearance

      0.030 to 0.065 mm (0.00118 to 0.00256 in.)

  3. REPLACE SPARK PLUG TUBE 

    HINT: 

    When using a new cylinder head sub-assembly, the spark plug tubes must be replaced.

    1. Apply adhesive onto the shaded area of a new spark plug tube.
      GTY646451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive
      *b Application Width
      *c Distance

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

      Standard application width

      1.0 to 3.0 mm (0.0394 to 0.118 in.)

      Distance

      1.0 to 7.0 mm (0.0394 to 0.276 in.)

      NOTE:
      • Install the spark plug tube within 3 minutes after applying adhesive.
      • Be careful not to deform the spark plug tube.
      • Be careful not to expose the seal to coolant for at least 1 hour after installing it.
    2. Using a wooden block and hammer, tap in the 4 spark plug tubes to the specified protrusion height.
      GTY509980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height

      Standard protrusion height

      112 mm (4.41 in.)

      NOTE:

      To avoid tapping in the spark plug tube too far, measure the protrusion height while tapping it.

  4. REPLACE RING PIN 
    NOTE:

    It is not necessary to remove the ring pin unless it is being replaced.

    1. Remove the 2 ring pins.
    2. Using a plastic-faced hammer, tap in 2 new ring pins to the cylinder head sub-assembly.
      GTY513975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height

      Standard protrusion height

      6.5 to 7.5 mm (0.256 to 0.295 in.)

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