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Replacement [01/2019 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REPLACE RING PIN 

    HINT: 

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

    1. Using a plastic hammer, tap in 2 new ring pins to the cylinder head sub-assembly.

      Standard Ring Pin

      Item Height Width Protrusion
      Ring pin 11.7 to 12.3 mm (0.461 to 0.484 in.) 12.0 mm (0.472 in.) 6.5 to 7.5 mm (0.256 to 0.295 in.)
      GTY540179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Top Side
      *b Width
      *c Height
      *d Protrusion Height
  2. REPLACE STUD BOLT 

    HINT: 

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

    1. Using E7 and E8 "TORX" socket wrenches, install the 9 stud bolts to the cylinder head sub-assembly.
      GTY941022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Intake Manifold Side *b Exhaust Manifold Side
      *c Cylinder Head Rear Side *d 55 mm (2.17 in.)
      *e 13 mm (0.512 in.) *f 26 mm (1.02 in.)
      *g 24 mm (0.945 in.) *h 49.5 mm (1.95 in.)
      *i 20 mm (0.787 in.) *j 42 mm (1.65 in.)

      Torque: 9.5 N.m (97 kgf/cm, 84 in.lbf) 

  3. REPLACE INTAKE VALVE GUIDE BUSH 
    1. Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 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.
      • SST: 09201-10000 
        1. 09201-01050
      • SST: 09950-70010 
        1. 09951-07100
      GTY539816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
    4. Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head sub-assembly.

      Standard Intake Valve Guide Bush Bore Diameter

      10.285 to 10.306 mm (0.40492 to 0.40575 in.)

      New Guide Bush Selection Chart

      Bush Size Bush Bore Diameter
      STD 10.333 to 10.344 mm (0.40681 to 0.40724 in.)
      O/S 0.05 10.383 to 10.394 mm (0.40878 to 0.40921 in.)

      HINT: 

      • If the intake valve guide bush bore diameter is more than 10.306 mm (0.40575 in.), machine the intake valve guide bush bore to a dimension of 10.335 to 10.356 mm (0.40689 to 0.40772 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 (0.40772 in.), replace the cylinder head sub-assembly.
      GTY588178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 212°F).
    6. Place the cylinder head sub-assembly on wooden blocks.
      WARNING:

      Be sure to wear protective gloves.

    7. Using SST and a hammer, tap in a new intake valve guide bush to the specified protrusion height.
      • SST: 09201-10000 
        1. 09201-01050
      • SST: 09950-70010 
        1. 09951-07100

      Standard Protrusion Height

      9.9 to 10.3 mm (0.390 to 0.406 in.)

      GTY574987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height
      *b Wooden Block
    8. Using a sharp 5.5 mm reamer, ream the intake valve guide bush to obtain the specified oil clearance.

      Standard Oil Clearance

      0.025 to 0.060 mm (0.000984 to 0.00236 in.)

      GTY588175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REPLACE EXHAUST VALVE GUIDE BUSH 
    1. Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 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
      GTY562723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
    4. Using a caliper gauge, measure the exhaust valve guide bush bore diameter of the cylinder head sub-assembly.

      Standard Exhaust Valve Guide Bush Bore Diameter

      10.285 to 10.306 mm (0.40492 to 0.40575 in.)

      New Guide Bush Selection Chart

      Bush Size Bush Bore Diameter
      STD 10.333 to 10.344 mm (0.40681 to 0.40724 in.)
      O/S 0.05 10.383 to 10.394 mm (0.40878 to 0.40921 in.)

      HINT: 

      • If the exhaust valve guide bush bore diameter is more than 10.306 mm (0.40575 in.), machine the exhaust valve guide bush bore to a dimension of 10.335 to 10.356 mm (0.40689 to 0.40772 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 (0.40772 in.), replace the cylinder head sub-assembly.
      GTY588174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 212°F).
    6. Place the cylinder head sub-assembly on wooden blocks.
      WARNING:

      Be sure to wear protective gloves.

    7. Using SST and a hammer, tap in a new exhaust valve guide bush to the specified protrusion height.
      • SST: 09201-10000 
        1. 09201-01050
      • SST: 09950-70010 
        1. 09951-07100

      Standard Protrusion Height

      11.15 to 11.55 mm (0.439 to 0.455 in.)

      GTY585073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height
      *b Wooden Block
    8. Using a sharp 5.5 mm reamer, ream the exhaust valve guide bush to obtain the specified oil clearance.

      Standard Oil Clearance

      0.030 to 0.065 mm (0.00118 to 0.00256 in.)

      GTY588181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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