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Cylinder Head: Replacement

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  1. REPLACE INTAKE VALVE GUIDE BUSH 
    1. Heat the cylinder head to 80 to 100°C (176 to 212°F).
    2. Place the cylinder head on wooden blocks.
      Fig 1: Heating The Cylinder Head
      G04484776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a hammer, tap out the guide bush.

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

      Fig 2: Taping Out Guide Bush
      G04484777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Heat the cylinder head to 80 to 100°C (176 to 212°F).
    5. Place the cylinder head on wooden blocks.
      Fig 3: Heating Cylinder Head
      G04484778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

      Standard diameter: 10.285 to 10.306 mm (0.4049 to 0.4058 in.) 

      If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4058 in.), machine the bush bore to the dimension of 10.335 to 10.365 mm (0.4068 to 0.4077 in.).

      Standard valve guide bush diameter 

      STANDARD VALVE GUIDE BUSH DIAMETER

      Condition Specified Condition
      STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
      O/S
      (0.05 mm)      		 10.383 to 10.394 mm (0.4088 to 0.4092 in.)
      Fig 4: Measuring Bush Bore Diameter Of Cylinder Head
      G04484779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the bushing bore diameter of the cylinder head is greater than 10.394 mm (0.4092 in.), replace the cylinder head.

    7. 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: 9.6 to 10.0 mm (0.378 to 0.394 in.) 

      Fig 5: Taping Guide Bush
      G04484780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using a sharp 5.5 mm reamer, ream the valve guide bush to the standard specified clearance between the valve guide bush and valve stem.

      Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0024 in.) 

      Fig 6: Reaming Valve Guide Bush
      G04484781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REPLACE EXHAUST VALVE GUIDE BUSH 
    1. Heat the cylinder head to 80 to 100°C (176 to 212°F).
    2. Place the cylinder head on wooden blocks.
      Fig 7: Heating Cylinder Head
      G04484782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a hammer, tap out the guide bush.

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

      Fig 8: Taping Out Guide Bush
      G04484783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Heat the cylinder head to 80 to 100°C (176 to 212°F).
    5. Place the cylinder head on wooden blocks.
      Fig 9: Heating Cylinder Head
      G04484784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

      Standard diameter: 10.285 to 10.306 mm (0.4049 to 0.4058 in.) 

      If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4058 in.), machine the bush bore to the dimension of 10.335 to 10.365 mm (0.4068 to 0.4077 in.).

      Fig 10: Measuring Bush Bore Diameter Of Cylinder Head
      G04484785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard valve guide bush diameter 

      STANDARD VALVE GUIDE BUSH DIAMETER

      Condition Specified Condition
      STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
      O/S
      (0.05 mm)      		 10.383 to 10.394 mm (0.4088 to 0.4092 in.)

      If the bushing bore diameter of the cylinder head is greater than 10.394 mm (0.4092 in.), replace the cylinder head.

    7. 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: 9.6 to 10.0 mm (0.378 to 0.394 in.) 

      Fig 11: Taping Guide Bush
      G04484786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using a sharp 5.5 mm reamer, ream the valve guide bush to the standard specified clearance between the valve guide bush and valve stem.

      Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.) 

  3. REPLACE STUD BOLT 
    NOTE: If the stud bolt is deformed or threads are damaged, replace it.
    1. Using E5 and E7 "Torx" socket wrenches, remove the 11 stud bolts.
      Fig 12: Reaming Valve Guide Bush
      G04484787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using E5 and E7 "Torx" socket wrenches, install the 11 stud bolts.
      Fig 13: Installing Stud Bolts
      G04484788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REPLACE RING PIN 
    1. Remove the 4 ring pins.
    2. Using a plastic-faced hammer, tap in 4 new ring pins to the specified protrusion height.

      Protrusion height: 3.0 mm (0.12 in.) 

      Fig 14: Taping Ring Pins
      G04484789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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