CYLINDER HEAD REPLACEMENT


  1. REPLACE INTAKE VALVE GUIDE BUSH


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

    2. Place the cylinder head on wooden blocks.

    3. A00JULDE01

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

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

    4. Using a caliper gauge, measure the intake valve guide 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.)
      Use Bush STD O/S 0.05

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

      If the bush bore diameter of the cylinder head is more than 10.356 mm (0.4077 in.), replace the cylinder head.

      New Guide Bush Diameter
      Item Specified Condition
      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

      Different bushes are used for the intake and exhaust.

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

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

    7. Place the cylinder head on wooden blocks.

    8. A00K0ZDE01
      Text in Illustration
      *1 Protrusion Height

      Using SST, tap in the intake valve guide bushes to the specified protrusion height.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Protrusion height
      9.10 to 9.90 mm (0.358 to 0.390 in.)
    9. A00K2A8

      Using a sharp 5.5 mm reamer, ream the valve guide bushes 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 to 80 to 100°C (176 to 212°F).

    2. Place the cylinder head on wooden blocks.

    3. A00JX16E01

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

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

    4. Using a caliper gauge, measure the exhaust valve guide 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.)
      Use Bush STD O/S 0.05

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

      If the bush bore diameter of the cylinder head is more than 10.356 mm (0.4077 in.), replace the cylinder head.

      New Guide Bush Diameter
      Item Specified Condition
      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

      Different bushes are used for the intake and exhaust.

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

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

    7. Place the cylinder head on wooden blocks.

    8. A00JVEXE01
      Text in Illustration
      *1 Protrusion Height

      Using SST, tap in the exhaust valve guide bushes to the specified protrusion height.

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Protrusion height
      9.10 to 9.90 mm (0.358 to 0.390 in.)
    9. A00JZIF

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

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

  3. REPLACE UNION


    1. Remove the union from the bank 1 cylinder head (front side) and bank 2 cylinder head (intake port side).

      A00K1J3E01
      Text in Illustration
      *A Front Side of RH *B Intake Side of LH

    2. Apply adhesive to 2 or 3 threads of the bolt ends of new unions.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Using a 12 mm deep socket wrench, install the 2 unions.

      Torque:
      15 N*m  { 150 kgf*cm, 11 ft.*lbf }

  4. REPLACE 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 around new tight plugs.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Using SST and a hammer, tap in the tight plugs to the standard depth.

      A00JTR3E01
      SST
      09950-60010   ( 09951-00250 )
      09950-70010   ( 09951-07150 )
      Standard depth
      1.7 to 2.7 mm (0.0669 to 0.106 in.)
      Text in Illustration
      *A RH *B LH
      *1 Standard Depth - -

  5. REPLACE STRAIGHT PIN

    Note

    If a straight pin is deformed, replace it.


    1. Using a plastic-faced hammer, tap in new straight pins as shown in the illustration.

      A00JWV9E01
      Protrusion height
      18.0 to 19.0 mm (0.708 to 0.748 in.)
      Text in Illustration
      *A RH *B LH
      *1 Protrusion Height - -

  6. REPLACE RING PIN

    Note

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


    1. A00JWCWE01
      Text in Illustration
      *A RH
      *B LH
      *1 Protrusion Height

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

      Protrusion height
      2.5 to 3.5 mm (0.0984 to 0.138 in.)

  7. REPLACE SPARK PLUG TUBE

    A00K1QOE01
    Text in Illustration
    *1 Adhesive
    *2 Distance

    Tech Tips

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


    1. Remove the spark plug tube.

    2. Apply adhesive to the end 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 (0.394 to 0.118 in.)
      Distance
      9.0 to 15.0 mm (0.354 to 0.590 in.)

      Note


      • 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 it.

    3. A00JZHVE01
      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 it.