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CYLINDER HEAD REPLACEMENT

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PROCEDURE


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    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. A01X0CBE04

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

      09201-10000 09201-01050
      09950-70010 09951-07100

    4. Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head.

      Standard Bush Bore Diameter
      Item Specified Condition
      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.)

    5. Select a new valve guide bush.

      New Guide Bush
      Item Specified Condition
      Bush Bore Diameter 10.285 to 10.306 mm (0.4049 to 0.4057 in.) 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
      Use Bush STD O/S 0.05

      If the bush bore diameter of the cylinder head is more than 10.306 mm (0.4057 in.), machine the bush bore diameter to 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 more than 10.356 mm (0.4077 in.), replace the cylinder head.

      New Guide Bush Diameter
      Item 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.)
      Tip:

      Different bushes are used for the intake and exhaust.

      Standard bush length
      41.3 to 41.7 mm (1.63 to 1.64 in.)

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

    7. Place the cylinder head on wooden blocks.

    8. A01X2JIE01

      Using SST, tap in the intake valve guide bushes to the specified protrusion height.

      09201-10000 09201-01050
      09950-70010 09951-07100
      Standard protrusion height
      9.10 to 9.90 mm (0.358 to 0.390 in.)
      Table 1. Text in Illustration
      *1 Protrusion Height
    9. A01X77M

      Using a sharp 5.5 mm reamer, ream the valve guide bushes to obtain the specified clearance.

      Standard oil clearance
      0.025 to 0.060 mm (0.000984 to 0.00236 in.)
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    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. A01WZHSE01

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

      09201-10000 09201-01050
      09950-70010 09951-07100

    4. Using a caliper gauge, measure the exhaust valve guide bush bore diameter of the cylinder head.

      Standard Bush Bore Diameter
      Item Specified Condition
      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.)

    5. Select a new valve guide bush.

      New Guide Bush
      Item Specified Condition
      Bush Bore Diameter 10.285 to 10.306 mm (0.4049 to 0.4057 in.) 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
      Use Bush STD O/S 0.05

      If the bush bore diameter of the cylinder head is more than 10.306 mm (0.4057 in.), machine the bush bore diameter to 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 more than 10.356 mm (0.4077 in.), replace the cylinder head.

      New Guide Bush Diameter
      Item 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.)
      Tip:

      Different bushes are used for the intake and exhaust.

      Standard bush length
      46.8 to 47.2 mm (1.84 to 1.86 in.)

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

    7. Place the cylinder head on wooden blocks.

    8. A01X3MIE05

      Using SST, tap in the exhaust valve guide bushes to the specified protrusion height.

      09201-10000 09201-01050
      09950-70010 09951-07100
      Standard protrusion height
      9.10 to 9.90 mm (0.358 to 0.390 in.)
      Table 2. Text in Illustration
      *1 Protrusion Height
    9. A01XBLB

      Using a sharp 5.5 mm reamer, ream the valve guide bushes to obtain the specified clearance.

      Standard oil clearance
      0.030 to 0.065 mm (0.00118 to 0.00256 in.)
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    REPLACE STRAIGHT PIN

    Note:

    If a straight pin is deformed, replace it.


    1. A01X5O2E03

      Using a plastic-faced hammer, tap in new straight pins as shown in the illustration.

      Table 3. Text in Illustration
      *1 Protrusion Height - -
      *a RH *b LH
      Standard protrusion height
      18.0 to 19.0 mm (0.708 to 0.748 in.)
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    REPLACE RING PIN

    Note:

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


    1. A01X4C5E03

      Using a plastic-faced hammer, tap in new ring pins to the specified protrusion height.

      Standard protrusion height
      2.5 to 3.5 mm (0.0984 to 0.138 in.)
      Table 4. Text in Illustration
      *1 Protrusion Height
      *a RH
      *b LH
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    REPLACE SPARK PLUG TUBE

    Tip:

    When using a new cylinder head, the spark plug tubes must be replaced.


    1. Apply adhesive to the end of a new spark plug tube.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
      Standard seal diameter
      1.0 to 3.0 mm (0.394 to 0.118 in.)
      Distance
      9.0 to 15.0 mm (0.354 to 0.590 in.)
      Table 5. Text in Illustration
      *1 Adhesive
      *2 Distance
      Note:

      • 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.

    2. A01X63RE01

      Using a wooden block and hammer, tap in the spark plug tube to the specified protrusion height.

      Standard protrusion height
      75.1 to 76.1 mm (2.96 to 3.00 in.)
      Table 6. Text in Illustration
      *1 Cylinder Head Top Surface
      *2 Protrusion Height
      Note:

      To avoid tapping in the spark plug tube too far, measure the protrusion height while tapping it.