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Replacement [10/2015 - ]: Procedure

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  1. REPLACE INTAKE VALVE GUIDE BUSH 
    1. Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 212°F).
      NOTE:

      Be sure to wear protective gloves.

    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
      GTY654195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head sub-assembly.

      Standard Intake Valve Guide Bush Bore Diameter

      10.285 to 10.306 mm (0.405 to 0.406 in.)

      Select a new intake valve guide bush (STD or O/S 0.05)

      Bush Size Bush Bore Diameter
      STD 10.285 to 10.306 mm (0.40492 to 0.40575 in.)
      O/S 0.05 10.335 to 10.356 mm (0.40689 to 0.40772 in.)

      If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.40575 in.), machine the intake valve guide bush bore of the cylinder head sub-assembly to a dimension of 10.335 to 10.356 mm (0.40689 to 0.40772 in.) to install an O/S 0.05 intake valve guide bush.

      If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.40772 in.), replace the cylinder head sub-assembly.

    5. Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 212°F).
      NOTE:

      Be sure to wear protective gloves.

    6. Using SST and a hammer, tap in the selected intake valve guide bush.
      • SST: 09201-10000 
        1. 09201-01050
      • SST: 09950-70010 
        1. 09951-07100
      GTY657743Courtesy 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.
      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 between 80 and 100°C (176 and 212°F).
      NOTE:

      Be sure to wear protective gloves.

    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
      GTY684842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a caliper gauge, measure the exhaust valve guide bush bore diameter of the cylinder head sub-assembly.

      Standard Exhaust Valve Guide Bush Bore Diameter

      10.285 to 10.306 mm (0.405 to 0.406 in.)

      Select a new exhaust valve guide bush (STD or O/S 0.05)

      Bush Size Bush Bore Diameter
      STD 10.285 to 10.306 mm (0.40492 to 0.40575 in.)
      O/S 0.05 10.335 to 10.356 mm (0.40689 to 0.40772 in.)

      If the exhaust valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.40575 in.), machine the exhaust valve guide bush bore of the cylinder head sub-assembly to a dimension of 10.335 to 10.356 mm (0.40689 to 0.40772 in.) to install an O/S 0.05 exhaust valve guide bush.

      If the exhaust valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.40772 in.), replace the cylinder head sub-assembly.

    5. Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 212°F).
      NOTE:

      Be sure to wear protective gloves.

    6. Using SST and a hammer, tap in the selected exhaust valve guide bush.
      • SST: 09201-10000 
        1. 09201-01050
      • SST: 09950-70010 
        1. 09951-07100
      GTY651761Courtesy 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.
      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 
    NOTE:

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

    1. Apply adhesive to a new spark plug tube as shown in the illustration.
      GTY517078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive 1324
      *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 engine oil for at least 1 hour after installing it.
    2. Using a wooden block and hammer, tap in the spark plug tube to the standard 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 

    HINT: 

    It is not necessary to remove the ring pins unless they are being replaced.

    1. Remove the 2 ring pins.
    2. Using a plastic 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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