CYLINDER BLOCK REPLACEMENT

PROCEDURE

1. REPLACE CYLINDER BLOCK TIGHT PLUG

   Note

   If coolant leaks from a tight plug or a plug is corroded, replace it.

   
   

   1. Remove the tight plugs.

   2. Apply adhesive to new tight plugs.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Do not start the engine for 1 hour after installation.

   3. Position A:

      Using a 14 mm steel bar and hammer, tap in the tight plug as shown in the illustration.

   4. Other positions:

      Using SST and a hammer, tap in the tight plugs as shown in the illustration.

      Position B

      SST

      09950-60010   ( 09951-00180 )

      09950-70010   ( 09951-07100 )

      Position C

      SST

      09950-60010   ( 09951-00190 )

      09950-70010   ( 09951-07100 )

      Position D

      SST

      09950-60010   ( 09951-00200 )

      09950-70010   ( 09951-07100 )

      Position E and H

      SST

      09950-60010   ( 09951-00350 )

      09950-70010   ( 09951-07100 )

      Position F

      SST

      09950-60010   ( 09951-00400, 09951-00450 )

      09950-70010   ( 09951-07100 )

      Position G

      SST

      09950-60010   ( 09951-00450 )

      09950-70010   ( 09951-07100 )

      

      *a	Right Side	*b	Left Side
      *c	Front Side	*d	Rear Side
      *e	Stops	-	-

2. REPLACE STRAIGHT PIN

   Note

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

   
   

   1. Remove the straight pins.

   2. Using a plastic-faced hammer, tap in new straight pins to the cylinder block sub-assembly.

      Standard Protrusion Height
      Item Specified Condition Pin A 7.5 mm (0.295 in.) or less Pin B 6 mm (0.234 in.) or less Pin C 12 mm (0.472 in.) or less

      

      *a	Front Side	*b	Rear Side
      *c	Pin A	*d	Pin B
      *e	Pin C	*f	18 mm (0.709 in.)
      *g	8 mm (0.3.15 in.)	*h	11 mm (0.433 in.)
      *i	6 mm (0.236 in.)	*j	22 mm (0.866 in.)
      *k	10 mm (0.394 in.)	*l	Protrusion height

3. REPLACE RING PIN

   Note

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

   
   

   1. Remove the ring pins.

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

      Standard Protrusion
      6 mm (0.236 in.) or less

      

      *a	Cylinder Head Side	*b	10.5 mm (0.413 in.)
      *c	15 mm (0.590 in.)	*d	6 mm (0.236 in.) or less

4. REPLACE TURBO WATER HOSE UNION

   Note

   If coolant leaks from a turbo water hose union or a turbo water hose union is corroded, replace the turbo water hose union.

   
   

   1. Remove the turbo water hose union from the cylinder block sub-assembly.

   2. Clean the cylinder block sub-assembly side hole and new turbo water hose union with non-residue solvent.

   3. 

      *a	Front
      *b	5.0 mm (0.197 in.)
      *c	2.0 mm (0.787 in.)
      *d	Adhesive

      Apply adhesive onto the shaded area of a turbo water hose union as shown in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Install the turbo water hose union within 3 minutes after applying adhesive.

   4. Set the turbo water hose union and tap it until the edge of the turbo water hose union fits against the chamfered part of the cylinder block sub-assembly as shown in the illustration.