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Cylinder Head: Replacement: 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.
    3. Using SST and a hammer, tap out the intake valve guide bushes.
      Fig 1: Identifying Intake Valve Guide Bush Component With SST
      GTY138013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09201-10000 
        • 09201-01050
      • SST: 09950-70010 
        • 09951-07100
    4. Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head.
      Fig 2: Identifying Bush Bore Diameter Of Cylinder Head
      GTY145628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Cylinder bore diameter

      10.285 to 10.306 mm (0.4049 to 0.4057 in.)

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

      Bush size Bush bore diameter
      STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
      O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)

      If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 valve guide bush.

      If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

    5. Heat the cylinder head to 80 to 100°C (176 to 212°F).
    6. Place the cylinder head on wooden blocks.
    7. Using SST, tap in new intake valve guide bushes to the specified protrusion height.
      Fig 3: Identifying Intake Valve Guide Bushes Components with SST
      GTY121802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09201-10000 
        • 09201-01050
      • SST: 09950-70010 
        • 09951-07100

      Protrusion height

      9.30 to 9.70 mm (0.3661 to 0.3819 in.)

    8. Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.
      Fig 4: Identifying Valve Guide Bush Component
      GTY127717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard oil clearance

      0.025 to 0.060 mm (0.0010 to 0.0023 in.)

  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.
    3. Using SST and hammer, tap out the exhaust valve guide bushes.
      • SST: 09201-10000 
        • 09201-01050
      • SST: 09950-70010 
        • 09951-07100
    4. Using a caliper gauge, measure the exhaust valve guide bush bore diameter of the cylinder head.
      Fig 5: Identifying Bush Bore Diameter Of Cylinder Head
      GTY136289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Cylinder bore diameter

      10.285 to 10.306 mm (0.4049 to 0.4057 in.)

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

      Bush size Bush bore diameter
      STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
      O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)

      If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 valve guide bush.

      If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

    5. Heat the cylinder head to 80 to 100°C (176 to 212°F).
    6. Place the cylinder head on wooden blocks.
    7. Using SST, tap in new exhaust valve guide bushes to the specified protrusion height.
      Fig 6: Identifying Valve Guide Bushes Component with SST
      GTY132216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09201-10000 
        • 09201-01050
      • SST: 09950-70010 
        • 09951-07100

      Protrusion height

      9.30 to 9.70 mm (0.3661 to 0.3819 in.)

    8. Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.
      Fig 7: Identifying Valve Guide Bushing Component
      GTY145207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard oil clearance

      0.030 to 0.065 mm (0.0012 to 0.0026 in.)

  3. REPLACE RING PIN 
    NOTE:

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

    1. Using a plastic hammer, tap in new ring pins to the specified protrusion height.
      Fig 8: Identifying Ring Pins Location
      GTY192524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specified protrusion height

      2.5 to 3.5 mm (0.098 to 0.138 in.)

  4. REPLACE STUD BOLT 
    NOTE:

    If the stud bolt is deformed or the threads are damaged, replace it.

    1. Using E6 and E8 "TORX" sockets, install the stud bolts.
      Fig 9: Identifying Stud Bolts Installation Position Location
      GTY146846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      for bolts A and B

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

      for bolt C

  5. REPLACE STRAIGHT PIN 
    NOTE:

    If the straight pin is deformed, replace it.

    1. Using a plastic hammer, tap in new straight pins as shown in the illustration.
      Fig 10: Identifying Straight Pins Location
      GTY189319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Protrusion height

      17.5 to 19.5 mm (0.689 to 0.768 in.)

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