LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2015 >> Highlander LE Plus, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2GR-FE) (Service Information) (Except Hybrid) (2 Of 2) >> Cylinder Head >> Replacement [12/2013 - 11/2016] >> Procedure

Replacement [12/2013 - 11/2016]: Procedure

  1. REPLACE INTAKE VALVE GUIDE BUSH 
    1. Heat the cylinder head sub-assembly to 80 to 100°C (176 to 212°F).
    2. Place the cylinder head sub-assembly on wooden blocks.
      WARNING:

      Be sure to wear protective gloves.

    3. Using SST and a hammer, tap out the intake valve guide bush.
      GTY446700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09201-10000 
        1. 09201-01050
      • SST: 09950-70010 
        1. 09951-07100
    4. Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head sub-assembly.
      GTY145628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Intake Valve Guide Bush Bore Diameter

      10.285 to 10.306 mm (0.4049 to 0.4057 in.)

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

      Bush Size Bush Bore Diameter
      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.)

      If the intake valve guide bush bore diameter is more than 10.306 mm (0.4057 in.), machine the intake valve guide bush bore to a dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 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 (0.4077 in.), replace the cylinder head sub-assembly.

    5. Heat the cylinder head sub-assembly to 80 to 100°C (176 to 212°F).
    6. Place the cylinder head sub-assembly on wooden blocks.
      WARNING:

      Be sure to wear protective gloves.

    7. Using SST, tap in a new intake valve guide bush.
      GTY423963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height
      • SST: 09201-10000 
        1. 09201-01050
      • SST: 09950-70010 
        1. 09951-07100

      Standard Protrusion Height

      9.30 to 9.70 mm (0.3661 to 0.3819 in.)

    8. Using a sharp 5.5 mm reamer, ream the intake valve guide bush to obtain the specified oil clearance.
      GTY127717Courtesy 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 80 to 100°C (176 to 212°F).
    2. Place the cylinder head sub-assembly on wooden blocks.
      WARNING:

      Be sure to wear protective gloves.

    3. Using SST and a hammer, tap out the exhaust valve guide bush.
      • SST: 09201-10000 
        1. 09201-01050
      • SST: 09950-70010 
        1. 09951-07100
    4. Using a caliper gauge, measure the exhaust valve guide bush bore diameter of the cylinder head sub-assembly.
      GTY136289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Exhaust Valve Guide Bush Bore Diameter

      10.285 to 10.306 mm (0.4049 to 0.4057 in.)

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

      Bush Size Bush Bore Diameter
      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.)

      If the exhaust valve guide bush bore diameter is more than 10.306 mm (0.4057 in.), machine the exhaust valve guide bush bore to a dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 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 (0.4077 in.), replace the cylinder head sub-assembly.

    5. Heat the cylinder head sub-assembly to 80 to 100°C (176 to 212°F).
    6. Place the cylinder head sub-assembly on wooden blocks.
      WARNING:

      Be sure to wear protective gloves.

    7. Using SST, tap in a new exhaust valve guide bush to the specified protrusion height.
      GTY431197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height
      • SST: 09201-10000 
        1. 09201-01050
      • SST: 09950-70010 
        1. 09951-07100

      Standard Protrusion Height

      9.30 to 9.70 mm (0.3661 to 0.3819 in.)

    8. Using a sharp 5.5 mm reamer, ream the exhaust valve guide bush to obtain the specified oil clearance.
      GTY145207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Oil Clearance

      0.030 to 0.065 mm (0.00118 to 0.00256 in.)

  3. REPLACE RING PIN 
    NOTE:

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

    1. Using a plastic hammer, tap in new ring pins.
      GTY423845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 1
      *B for Bank 2

      Standard Protrusion Height

      2.5 to 3.5 mm (0.0984 to 0.138 in.)

  4. REPLACE STUD BOLT 
    NOTE:

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

    1. Using E6 and E8 "TORX" socket wrenches, install the stud bolts.
      GTY434579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Bank 1 Rear Side *B Bank 1 Intake Side
      *C Bank 2 Intake Side *D Bank 1 Exhaust Side
      *E Bank 2 Exhaust Side *F Bank 2 Rear Side

      Bolt (A) and (B) 

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

      Bolt (C) 

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

  5. REPLACE STRAIGHT PIN 
    NOTE:

    If a straight pin is deformed, replace it.

    1. Using a plastic hammer, tap in new straight pins as shown in the illustration.
      GTY444642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 1 *B for Bank 2

      Standard Protrusion Height

      17.5 to 19.5 mm (0.689 to 0.768 in.)

scientia non olet · About LEMON Manuals