CYLINDER HEAD REPLACEMENT

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.

    3. A01GC45E01

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

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

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

      Standard bush bore diameter
      10.285 to 10.306 mm (0.405 to 0.406 in.)
      Select New Guide Bush
      Bush Size Bush 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 bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.406 in.), machine the bush bore to a diameter of 10.335 to 10.356 mm (0.407 to 0.408 in.) in order to install an O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.408 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.

    7. A01GB3QC08
      *1 Protrusion Height

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Protrusion height
      9.9 to 10.3 mm (0.390 to 0.406 in.)
    8. A01GAIM

      Using a sharp 5.5 mm reamer, ream the intake guide bush to obtain the standard clearance between the guide bush and valve stem.

      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.

    3. A01GA0DE01

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

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

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

      Standard bush bore diameter
      10.285 to 10.306 mm (0.405 to 0.406 in.)
      Select New Guide Bush
      Bush Size Bush 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 bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.406 in.), machine the bush bore to a diameter of 10.335 to 10.356 mm (0.407 to 0.408 in.) in order to install an O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.408 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.

    7. A01GCH2C08
      *1 Protrusion Height

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Protrusion height
      11.15 to 11.55 mm (0.439 to 0.455 in.)
    8. A01GAE6

      Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard clearance between the guide bush and valve stem.

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

  3. REPLACE SPARK PLUG TUBE

    Note

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


    1. A01GDFPC05
      *1 Adhesive
      *2 Seal Diameter
      *3 Distance

      Apply adhesive onto the shaded area 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 (0.0394 to 0.118 in.)
      Distance from end of tube
      1.0 to 7.0 mm (0.0394 to 0.294 in.)

      Note


      • Install the spark plug tube within 3 minutes after applying adhesive.

      • 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 the tube.

    2. A01G9ZFC06
      *1 Protrusion Height

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

      Standard protrusion height
      122 mm (4.80 in.)

      Note

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

  4. REPLACE RING PIN

    Note

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


    1. A01GCDLC10
      *1 Protrusion Height
      *2 Width
      *3 Height

      Remove the ring pins.

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

      Standard Ring Pin
      Height Width Protrusion
      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.)