Engine Unit: Replacement

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

REPLACE SPARK PLUG TUBE GASKET
1. Pry up the claws of the ventilation baffle plate.
  
  Fig 1: Prying Up Claws Of Ventilation Baffle Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver with its tip taped and a hammer, tap out the 6 spark plug tube gaskets.
  
  Fig 2: Tapping Out Spark Plug Tube Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a 32 mm socket wrench, tap in 6 new spark plug tube gaskets to the head covers.
  NOTE:
  - Keep the lip free from foreign matter.
  - Do not tap on the oil seal at an angle.
4. Return the claw of the ventilation baffle plate to its original position.
REPLACE ENGINE REAR OIL SEAL
1. Place the oil seal retainer on wooden blocks.
2. Using a screwdriver and a hammer, tap out the oil seal.
  
  Fig 4: Tapping Out Rear Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.
  SST 09223-15030
  NOTE:
  - Keep the lip free from foreign matter.
  - Do not tap on the oil seal at an angle.
    
    Fig 5: Tapping In Rear Oil Seal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE CONNECTING ROD SMALL END BUSH
1. Using SST and a press, push out the bush.
  SST 09222-30010
  
  Fig 6: Identifying Small End Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the oil holes of the new bush and connecting rod.
  
  Fig 7: Aligning Oil Holes Of Small End Bush And Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, push in the bush.
  SST 09222-30010
  
  Fig 8: Identifying Small End Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a pin hole grinder, hone the bush to obtain the standard specified clearance between the bush and piston pin.
  
  Fig 9: Honing Small End Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Coat the piston pin with engine oil. Push the piston pin into the connecting rod with your thumb to check that the piston pin fits at normal room temperature.
  
  Fig 10: Pushing Piston Pin Into Connecting Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REPLACE INTAKE VALVE GUIDE BUSH

Heat the cylinder head to approximately 80 to 100°C (176 to 212°F).
Place the cylinder head on wooden blocks.
Using SST and a hammer, tap out the valve guide bush.
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)

Fig 11: Tapping Out Valve Guide Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a caliper gauge, measure the bush bore diameter of the cylinder head.
Standard cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.)

Fig 12: Measuring Bush Bore Diameter Of Cylinder Head
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard bush bore diameter

BUSH BORE DIAMETER SPECIFICATION

Bush Size	Specified Condition
Use STD	10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Use O/S 0.05	10.285 to 10.306 mm (0.4049 to 0.4057 in.)

HINT:

If the bush bore diameter of the cylinder head is greater than 10.344 mm (0.4072 in.), machine the bush bore diameter to between 10.383 to 10.394 mm (0.4088 to 0.4092 in.).
If the bush bore diameter of the cylinder head is greater than 10.344 mm (0.4072 in.), replace the cylinder head.

Heat the cylinder head to approximately 80 to 100°C (176 to 212°F).
Using SST and a hammer, tap in a new guide bush to the specified protrusion height.
Standard protrusion height: 9.1 to 9.9 mm (0.3582 to 0.3900 in.)

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

Fig 13: Tapping In Guide Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem.

Fig 14: Reaming Guide Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REPLACE EXHAUST VALVE GUIDE BUSH

Heat the cylinder head to approximately 80 to 100°C (176 to 212°F).
Place the cylinder head on wooden blocks.
Using SST and a hammer, tap out the valve guide bush.
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)

Fig 15: Tapping Out Valve Guide Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a caliper gauge, measure the bush bore diameter of the cylinder head.
Standard cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.)

Fig 16: Measuring Bush Bore Diameter Of Cylinder Head
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard bush bore diameter

BUSH BORE DIAMETER SPECIFICATION

Bush Size	Specified Condition
Use STD	10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Use O/S 0.05	10.285 to 10.306 mm (0.4049 to 0.4057 in.)

HINT:

If the bush bore diameter of the cylinder head is greater than 10.344 mm (0.4072 in.), machine the bush bore diameter to between 10.383 to 10.394 mm (0.4088 to 0.4092 in.).
If the bush bore diameter of the cylinder head is greater than 10.344 mm (0.4072 in.), replace the cylinder head.

Heat the cylinder head to approximately 80 to 100°C (176 to 212°F).
Using SST and a hammer, tap in a new guide bush to the specified protrusion height.
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)

Standard protrusion height: 9.30 to 9.70 mm (0.3661 to 0.3819 in.)

Fig 17: Tapping In Guide Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem.

Fig 18: Reaming Guide Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REPLACE CYLINDER BLOCK TIGHT PLUG
NOTE: If water leaks from the tight plug or the plug corrodes, replace it.
1. Remove the tight plugs.
2. Apply adhesive around the tight plug.
  Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
  
  Fig 19: Applying Adhesive Around Tight Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a hammer, tap in 2 new tight plugs as shown in the illustration.
  SST 09950-60010 (09951-00340), 09950-70010 (09951-07100)
  
  Fig 20: Identifying Tight Plugs Into Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE CYLINDER BLOCK STUD BOLT
NOTE: If a stud bolt is deformed or the threads are damaged, replace it.
1. Remove the stud bolts.
2. Using an E8 "torx" socket wrench, install the stud bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 21: Identifying Stud Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REPLACE CYLINDER BLOCK STRAIGHT PIN

NOTE: It is not necessary to remove the straight pin unless it is being replaced.

Remove the straight pin.

Using a plastic-faced hammer, tap in new straight pins to the cylinder block.

Standard protrusion

CYLINDER BLOCK STRAIGHT PIN

Item	Specified Condition
Pin A	23 mm (0.91 in.)
Pin B	6 mm (0.24 in.)
Pin C	11 mm (0.43 in.)
Pin D	9 mm (0.35 in.)

Fig 22: Identifying Cylinder Block Straight Pin

REPLACE CYLINDER HEAD RING PIN
NOTE: It is not necessary to remove the ring pin unless it is being replaced.
1. Remove the ring pins.
2. Using a plastic-faced hammer, tap in a new ring pin until the pin stops.
Fig 23: Identifying Cylinder Head Ring Pins
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE CYLINDER HEAD 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.
  Torque:
  
  10 N*m (102 kgf*cm, 7 ft.*lbf) for stud bolts A and B
  
  4.0 N*m (41 kgf*cm, 35 in.*lbf) for stud bolt C
  
  Fig 24: Identifying Cylinder Head Stud Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE CYLINDER HEAD SET STRAIGHT PIN
NOTE: It is not necessary to remove the straight pin unless it is being replaced.
1. Using a plastic-faced hammer, tap in a new straight pin as shown in the illustration.
  Standard protrusion height: 18.0 to 19.0 mm (0.71 to 0.75 in.)
  
  Fig 25: Identifying Cylinder Head Set Straight Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002