CYLINDER HEAD REPLACEMENT


  1. REPLACE INTAKE VALVE SEAT


    1. A01CJ13E03
      Text in Illustration
      *1 Brass Block
      *2 Valve Seat
      *3 Valve
      *a Grind these Points with a Grinder
      *b Weld Application Point

      As shown in the illustration, grind the 3 points on the circumference of an unneeded valve and weld it to the valve seat.

      Note

      To protect the lower surface of the cylinder head from welding spatters, be sure to apply grease to the cylinder head before welding.

    2. Place a brass block on the top of the valve stem and strike it with a hammer to remove the valve seat.

      CAUTION:

      When striking, metal shards may fly off on impact. Wear safety glasses to protect your eyes.

    3. A01CHV9E01

      Using a caliper gauge and vernier caliper, measure the dimensions of the valve seat installation holes.

      Standard intake valve seat dimensions
      A
      36.00 to 36.015 mm (1.4173 to 1.4179 in.)
      B
      8.4 to 8.6 mm (0.3307 to 0.3386 in.)

      If the result is not specified, replace the cylinder head.

    4. Heat the cylinder head up to 80 to 100°C (176 to 212°F).

    5. A01CHHZE02

      Using SST and a hammer, lightly tap new valve seats into the cylinder head.

      SST
      09950-60010   ( 09951-00300, 09951-00360, 09952-06010 )
      09950-70010   ( 09951-07100 )
      SST 1 09951-07100
      SST 2 09952-06010
      SST 3 09951-00360
      SST 4 09951-00300

    6. Using SST and a hammer, completely tap in the valve seats.

      SST
      09950-60010   ( 09951-00300, 09951-00360, 09952-06010 )
      09950-70010   ( 09951-07100 )

  2. REPLACE EXHAUST VALVE SEAT


    1. A01CJ13E04
      Text in Illustration
      *1 Brass Block
      *2 Valve Seat
      *3 Valve
      *a Grind these Points with a Grinder
      *b Weld Application Point

      As shown in the illustration, grind the 3 points on the circumference of an unneeded valve and weld it to the valve seat.

      Note

      To protect the lower surface of the cylinder head from welding spatters, be sure to apply grease to the cylinder head before welding.

    2. Place a brass block on the top of the valve stem and strike it with a hammer to remove the valve seat.

      CAUTION:

      When striking, metal shards may fly off on impact. Wear safety glasses to protect your eyes.

    3. A01CGPDE02

      Using a caliper gauge and vernier caliper, measure the dimensions of the valve seat installation holes.

      Standard exhaust valve seat dimensions
      A
      36.00 to 36.015 mm (1.4173 to 1.4179 in.)
      B
      8.4 to 8.6 mm (0.3307 to 0.3386 in.)

      If the result is not specified, replace the cylinder head.

    4. Heat the cylinder head up to 80 to 100°C (176 to 212°F).

    5. A01CHTNE02

      Using SST and a hammer, lightly tap new valve seats into the cylinder head.

      SST
      09950-60010   ( 09951-00250, 09951-00320, 09952-06010 )
      09950-70010   ( 09951-07100 )
      SST 1 09951-07100
      SST 2 09952-06010
      SST 3 09951-00360
      SST 4 09951-00300

    6. Using SST and a hammer, completely tap in the valve seats.

      SST
      09950-60010   ( 09951-00250, 09951-00320, 09952-06010 )
      09950-70010   ( 09951-07100 )

  3. REPLACE INTAKE VALVE GUIDE BUSH


    1. Heat the cylinder head up to 80 to 100°C (176 to 212°F).

    2. A01CJ06E01

      Using SST and a hammer, tap out the valve guide bush.

      SST
      09201-10000   ( 09201-01070 )
      09950-70010   ( 09951-07100 )
    3. A01CIWC

      Using a caliper gauge, measure the inside diameter of the guide bush.

      Standard bush inside diameter
      13.000 to 13.018 mm (0.5118 to 0.5125 in.)

      Tech Tips

      If the bush bore diameter of the cylinder head is greater than 13.02 mm (0.5125 in.), replace the cylinder head.

    4. Heat the cylinder head up to 80 to 100°C (176 to 212°F).

    5. A01CII6E01

      Using SST, tap in a new valve guide bush to the specified protrusion height.

      SST
      09201-10000   ( 09201-01070 )
      09950-70010   ( 09951-07100 )
      Standard protrusion height
      26.4 to 26.8 mm (1.039 to 1.055 in.)

      Note

      Do not tap in the guide bush excessively.

    6. Using a reamer, ream the inside of the valve guide bush to the specified oil clearance between the valve guide bush and valve stem.

      Standard oil clearance
      0.028 to 0.058 mm (0.00110 to 0.00228 in.)
      Maximum oil clearance
      0.12 mm (0.00472 in.)

  4. REPLACE EXHAUST VALVE GUIDE BUSH


    1. Heat the cylinder head up to 80 to 100°C (176 to 212°F).

    2. A01CJ7QE01

      Using SST and a hammer, tap out the valve guide bush.

      SST
      09201-10000   ( 09201-01070 )
      09950-70010   ( 09951-07100 )
    3. A01CIWC

      Using a caliper gauge, measure the inside diameter of the guide bush.

      Standard bush inside diameter
      13.000 to 13.018 mm (0.5118 to 0.5125 in.)

      Tech Tips

      If the bush bore diameter of the cylinder head is greater than 13.02 mm (0.5125 in.), replace the cylinder head.

    4. Heat the cylinder head up to 80 to 100°C (176 to 212°F).

    5. A01CJGLE01

      Using SST, tap in a new valve guide bush to the specified protrusion height.

      SST
      09201-10000   ( 09201-01070 )
      09950-70010   ( 09951-07100 )
      Standard protrusion height
      26.4 to 26.8 mm (1.039 to 1.055 in.)

      Note

      Do not tap in the guide bush excessively.

    6. Using a reamer, ream the inside of the valve guide bush to the specified oil clearance between the valve guide bush and valve stem.

      Standard oil clearance
      0.053 to 0.083 mm (0.00209 to 0.00327 in.)
      Maximum oil clearance
      0.15 mm (0.00591 in.)

  5. REPLACE INJECTION NOZZLE SEAT


    1. A01CIZ0E01

      Using SST, remove the injection nozzle seat.

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

    2. Remove the O-ring from the cylinder head sub-assembly.

    3. A01CI00E02
      Text in Illustration
      *1 Cylinder Head
      *2 O-ring
      *3 Nozzle Seat

      Apply a light coat of engine oil to new O-rings, and install them into the cylinder head.

      Note

      Be sure to install new O-rings. Reusing O-rings may cause water or gas leakage and lead to overheating or a cracked cylinder head.

    4. A01CGK0E02
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to new nozzle seats.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the installation surfaces of the cylinder head and nozzle seats.

      • Be sure to install new nozzle seats. Reusing nozzle seats may cause water or gas leakage and lead to overheating or a cracked cylinder head.

    5. A01CGM7E02
      Text in Illustration
      *1 Nozzle Seat

      Using SST, install the nozzle seat onto the cylinder head.

      SST
      09260-69015
      09268-06020
    6. A01CID6E02
      Text in Illustration
      *1 Nozzle Seat

      Using SST, stake the nozzle seat.

      SST
      09260-69015
      09268-06010

      Note

      Put a container under the cylinder head to prevent the steel ball from being lost.

    7. A01CJDIE02
      Text in Illustration
      *a Protrusion

      Install the injectors onto the cylinder head. Using a vernier caliper, measure the protrusion of the injectors from the lower surface of the cylinder head.

      Standard
      2.45 to 2.95 mm (0.0964 to 0.1161 in.)

  6. REPLACE STUD BOLT


    1. Using E8 and E10 "TORX" socket wrenches, remove the stud bolts.

    2. Using E8 and E10 "TORX" socket wrenches, install the stud bolts.

      A01CHUIE03
      Text in Illustration
      *a Intake Manifold Side *b Exhaust Manifold Side
      Torque:
      Bolt A
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      Bolt B
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }