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.

      CAUTION:

      Be sure to wear protective gloves.

    3. A001TA4E01

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
    4. A001XUG

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

      Standard Intake Valve Guide Bush Bore Diameter
      10.285 to 10.306 mm (0.4049 to 0.4057 in.)
      Select a new intake valve guide bush (STD or O/S 0.05)
      Bush Size Bush Bore 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.)

      Tech Tips


      • If the intake valve guide bush bore diameter is more than 10.306 mm (0.4057 in.), machine the intake valve guide bush bore to a dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 intake valve guide bush.

      • If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.4077 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.

      CAUTION:

      Be sure to wear protective gloves.

    7. A001XCVC03
      *a Protrusion Height

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Standard Protrusion Height
      9.9 to 10.3 mm (0.390 to 0.406 in.)
    8. A001XW9

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

      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.

      CAUTION:

      Be sure to wear protective gloves.

    3. A001V5JE01

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
    4. A001T0CN01

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

      Standard Exhaust Valve Guide Bush Bore Diameter
      10.285 to 10.306 mm (0.4049 to 0.4057 in.)
      Select a new exhaust valve guide bush (STD or O/S 0.05)
      Bush Size Bush Bore 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.)

      Tech Tips


      • If the exhaust valve guide bush bore diameter is more than 10.306 mm (0.4057 in.), machine the exhaust valve guide bush bore to a dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 exhaust valve guide bush.

      • If the exhaust valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.4077 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.

      CAUTION:

      Be sure to wear protective gloves.

    7. A001XSYC03
      *a Protrusion Height

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Standard Protrusion Height
      11.15 to 11.55 mm (0.4390 to 0.4547 in.)
    8. A001T1X

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

      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. A001VQIC12
      *a 1.0 to 3.0 mm (0.0394 to 0.118 in.)
      *b 1.0 to 13.0 mm (0.0394 to 0.5118 in.)

      Apply adhesive to a new spark plug tube as shown in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
      Standard Application Width
      1.0 to 3.0 mm (0.0394 to 0.118 in.)

      Note


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

      • Be careful not to deform the spark plug tube.

      • Be careful not to expose the adhesive to engine oil for at least 1 hour after installing the spark plug tube.

    2. A001VB1C10
      *a 122 mm (4.80 in.)

      Using a wooden block and hammer, tap in the spark plug tube.

      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 the ring pins unless they are being replaced.


    1. A001XUUC13
      *a Top Side
      *b Width
      *c Height
      *d Protrusion Height

      Using a plastic hammer, tap in 2 new ring pins.

      Standard Ring Pin
      Item Height Width Protrusion
      Ring pin 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.)