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Cylinder Head: Replacement

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  1. REPLACE INTAKE VALVE GUIDE BUSH 
    1. Heat the cylinder head to approximately 80 to 100°C (176 to 212°F).
    2. Place the cylinder head on wooden blocks.
    3. Using SST and a hammer, tap out the valve guide bush.

      SST 09201 -01055, 09950-70010 (09951 -07100) 

      Fig 1: Tapping Out Valve Guide Bush
      G05997768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

      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 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 is 10.356 mm (0.408 in.) or more, replace the cylinder head.

      Fig 2: Measuring Bush Bore Diameter Of Cylinder Head
      G05997769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Select a new guide bush (STD or O/S 0.05), and measure its diameter.
    6. Machine the bush bore of the cylinder head to the diameter of the selected guide bush.

      Bush Bore Diameter 

      BUSH BORE DIAMETER SPECIFICATION

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

      Standard bush length: 41.3 to 41.7 mm (1.626 to 1.642 in.) 

    7. Heat the cylinder head to approximately 80 to 100°C (176 to 212°F).
    8. Using SST and a hammer, tap in the selected guide bush to the standard protrusion height.

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

      Standard protrusion height: 14.8 to 15.2 mm (0.582 to 0.598 in.) 

      Fig 3: Measuring Protrusion Height Of Cylinder Head
      G05997770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard oil clearance between the guide bush and valve stem.

      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 to approximately 80 to 100°C (176 to 212°F).
    2. Place the cylinder head on wooden blocks.
      Fig 4: Reaming Guide Bush
      G05997771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a hammer, tap out the valve guide bush.

      SST 09201-01055, 09950-70010 (09951-07100) 

      Fig 5: Tapping Out Valve Guide Bush
      G05997772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

      Standard bush bore diameter: 10.285 to 10.306 mm (0.405 to 0.406 in.) 

      If the bush diameter of the cylinder head 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 is 10.356 mm (0.408 in.) or more, replace the cylinder head.

      Fig 6: Measuring Bush Bore Diameter Of Cylinder Head
      G05997773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Select a new guide bush (STD or O/S 0.05), and measure its diameter.
    6. Machine the bush bore of the cylinder head to the diameter of the selected guide bush.

      Bush Bore Diameter 

      BUSH BORE DIAMETER SPECIFICATION

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

      Standard bush length: 46.8 to 47.2 mm (1.843 to 1.858 in.) 

    7. Heat the cylinder head to approximately 80 to 100°C (176 to 212°F).
    8. Using SST and a hammer, tap in the selected guide bush to the standard protrusion height.

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

      Standard protrusion height: 14.2 to 14.6 mm (0.559 to 0.575 in.) 

      Fig 7: Tapping In Guide Bush
      G05997774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard oil clearance between the guide bush and valve stem.

      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, the spark plug tubes must be replaced.

    Fig 8: Reaming Guide Bush
    G05997775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the spark plug tube.
    2. Apply adhesive onto the shaded area of a new spark plug tube.

      Adhesive: 

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. 

      Standard application width: 

      2.0 mm (0.0787 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.
      Fig 9: Applying Adhesive Onto Shaded Area Of Spark Plug Tube
      G05997776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a wooden block and hammer, tap in the spark plug tube to the specified 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 ring pins.
      Fig 10: Measuring Protrusion Height Of Spark Plug Tube
      G05997777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic-faced hammer, tap in new ring pins to the cylinder head.

      Standard protrusion height: 6.5 to 7.5 mm (0.256 to 0.295 in.) 

    Fig 11: Identifying Protrusion Height
    G05997778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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