CYLINDER HEAD REPLACEMENT


  1. REPLACE INTAKE VALVE GUIDE BUSH


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

    2. Place the cylinder head on wooden blocks.

    3. A01597GE03

      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.

      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.)
      Bush to be Used STD O/S 0.05

      If the bush bore diameter of the cylinder head is more than 10.306 mm (0.406 in.), machine the bush bore diameter to between 10.335 and 10.356 mm (0.4069 and 0.4077 in.).

      If the bush bore diameter of the cylinder head is more than 10.356 mm (0.408 in.), replace the cylinder head sub-assembly.

      New Guide Bush Diameter
      Item 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.)

      Tech Tips

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

    6. A0158YLE03
      Text in Illustration
      *1 Protrusion Height

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Standard protrusion height
      14.3 to 14.7 mm (0.563 to 0.579 in.)
    7. A0157K7

      Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard oil clearance between the intake valve guide bush and intake 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 to approximately 80 to 100°C (176 to 212°F).

    2. Place the cylinder head on wooden blocks.

    3. A015AJGE03

      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.

      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 exhaust 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.)
      Bush to be Used STD O/S 0.05

      If the bush bore diameter of the cylinder head is more than 10.306 mm (0.406 in.), machine the bush bore diameter to between 10.335 and 10.356 mm (0.4069 and 0.4077 in.).

      If the bush bore diameter of the cylinder head is more than 10.356 mm (0.408 in.), replace the cylinder head sub-assembly.

      New Guide Bush Diameter
      Item 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.)

      Tech Tips

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

    6. A0157MRE03
      Text in Illustration
      *1 Protrusion Height

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Standard protrusion height
      14.3 to 14.7 mm (0.563 to 0.579 in.)
    7. A015E7G

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

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

  3. REPLACE SPARK PLUG TUBE

    Tech Tips

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


    1. A0155ZTE06
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
      Standard seal diameter
      15 mm (0.591 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 spark plug tube.

    2. A0155E7E02
      Text in Illustration
      *1 Cylinder Head Top Surface
      *2 Protrusion Height

      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.)

      Note

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

  4. 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 head.

      A015DUIE02
      Text in Illustration
      *A for Bank 1 *B for Bank 2
      *1 Width *2 Height
      *3 Protrusion Height - -
      Standard Ring Pin
      Item Height Width Protrusion
      Ring pin A 11 mm (0.433 in.) 11 mm (0.433 in.) 5.5 to 6.5 mm (0.217 to 0.256 in.)
      Ring pin B 10 mm (0.394 in.) 11 mm (0.433 in.) 3.5 to 6.5 mm (0.138 to 0.256 in.)