CYLINDER HEAD REPLACEMENT

PROCEDURE


  1. REPLACE INTAKE VALVE GUIDE BUSH


    1. A00Y6I3

      Gradually heat the cylinder head sub-assembly to approximately 80 to 100°C (176 to 212°F).

    2. Place the cylinder head sub-assembly on wooden blocks.

    3. A00YAYMN01

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

      SST
      09201-10000
      09950-70010
    4. A00Y4ZE

      Using a caliper gauge, measure the bush bore diameter of the cylinder head sub-assembly.

      If the bush bore diameter of the cylinder head sub-assembly is more than 11.006 mm (0.433 in.), machine the bush bore diameter to between 11.035 and 11.056 mm (0.434 and 0.435 in.).

      If the bush bore diameter of the cylinder head sub-assembly is more than 11.056 mm (0.435 in.), replace the cylinder head sub-assembly.

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

      Guide Bush
      Bush Size Specified Condition
      Use STD 10.985 to 11.006 mm (0.432 to 0.433 in.)
      Use O/S 0.05 11.035 to 11.056 mm (0.434 to 0.435 in.)
    6. A00Y6I3

      Gradually heat the cylinder head sub-assembly to approximately 80 to 100°C (176 to 212°F).

    7. Place the cylinder head sub-assembly on wooden blocks.

    8. A00Y98MN01

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

      SST
      09201-10000
      09950-70010
      Standard Protrusion Height (A)
      9.0 to 9.4 mm (0.354 to 0.370 in.)
    9. A00Y4V8C02
      *1 Sharp 6.0 mm Reamer

      Using a sharp 6.0 mm reamer, ream the intake valve guide bush to obtain the standard specified clearance between the intake valve guide bush and intake valve stem.

  2. REPLACE EXHAUST VALVE GUIDE BUSH


    1. A00Y6I3

      Gradually heat the cylinder head sub-assembly to approximately 80 to 100°C (176 to 212°F).

    2. Place the cylinder head sub-assembly on wooden blocks.

    3. A00Y650N01

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

      SST
      09201-10000
      09950-70010
    4. A00Y4ZE

      Using a caliper gauge, measure the bush bore diameter of the cylinder head sub-assembly.

      If the bush bore diameter of the cylinder head sub-assembly is more than 11.006 mm (0.433 in.), machine the bush bore diameter to between 11.035 and 11.056 mm (0.434 and 0.435 in.).

      If the bush bore diameter of the cylinder head sub-assembly is more than 11.056 mm (0.435 in.), replace the cylinder head sub-assembly.

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

      Guide Bush
      Bush Size Specified Condition
      Use STD 10.985 to 11.006 mm (0.432 to 0.433 in.)
      Use O/S 0.05 11.035 to 11.056 mm (0.434 to 0.435 in.)
    6. A00Y6I3

      Gradually heat the cylinder head sub-assembly to approximately 80 to 100°C (176 to 212°F).

    7. Place the cylinder head sub-assembly on wooden blocks.

    8. A00YANDN01

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

      SST
      09201-10000
      09950-70010
      Standard Protrusion Height (A)
      9.0 to 9.4 mm (0.354 to 0.370 in.)
    9. A00Y4V8C02
      *1 Sharp 6.0 mm Reamer

      Using a sharp 6.0 mm reamer, ream the exhaust valve guide bush to obtain the standard specified clearance between the exhaust valve guide bush and exhaust valve stem.

  3. REPLACE CYLINDER HEAD RING PIN

    Tech Tips

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


    1. Remove the cylinder head ring pin.

    2. Using a plastic hammer, tap in a new cylinder head ring pin until the pin stops.

      A00Y4VQC01
      *A Intake Manifold Side *B Cylinder Head Cover Side
      *a Pin A *b Pin B
      Standard Protrusion
      Item Specified Condition
      Pin A 3.9 to 5.5 mm (0.154 to 0.217 in.)
      Pin B 2.5 to 3.5 mm (0.0984 to 0.138 in.)

  4. REPLACE NO. 1 STRAIGHT SCREW PLUG WITH HEAD


    1. A00Y7R3

      Using a 6 mm hexagon wrench, remove the 4 No.1 straight screw plug with heads.

    2. Apply adhesive to 4 new No. 1 straight screw plug with heads.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Using a 6 mm hexagon wrench, install the 4 No. 1 straight screw plug with heads.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  5. REPLACE CYLINDER HEAD STUD BOLT

    Tech Tips

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


    1. Remove the cylinder head stud bolts.

    2. Using an E8 "TORX" socket wrench, install new cylinder head stud bolts (A) and (C).

      A00Y6TKC02
      *A Cylinder Head Cover Side *B Intake Manifold Side
      *C Exhaust Manifold Side - -
      Torque:
      Stud Bolt (A)
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Stud Bolt (C)
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    3. Install new cylinder head stud bolt (B).

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }