CYLINDER HEAD REPLACEMENT

PROCEDURE


  1. REPLACE INTAKE VALVE GUIDE BUSH


    1. Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 212°F).

      Note

      Be sure to wear protective gloves.

    2. Place the cylinder head sub-assembly on wooden blocks.

    3. A01R3UXN04

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

      SST
      09201-01055
      09950-70010   ( 09951-07100 )

    4. 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 (0.405 to 0.406 in.)
      Select a new intake valve guide bush (STD or O/S 0.05)
      Bush Size Bush Bore Diameter
      STD 10.285 to 10.306 mm (0.40492 to 0.40575 in.)
      O/S 0.05 10.335 to 10.356 mm (0.40689 to 0.40772 in.)

      If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.40575 in.), machine the intake valve guide bush bore of the cylinder head sub-assembly to a dimension of 10.335 to 10.356 mm (0.40689 to 0.40772 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 (0.40772 in.), replace the cylinder head sub-assembly.

    5. Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 212°F).

      Note

      Be sure to wear protective gloves.

    6. A01R7DLC04
      *a Protrusion Height

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Standard Protrusion Height
      14.85 to 15.10 mm (0.585 to 0.594 in.)
    7. A01R6D7

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

      Note

      Be sure to wear protective gloves.

    2. Place the cylinder head sub-assembly on wooden blocks.

    3. A01R5ZWN04

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

      SST
      09201-01055
      09950-70010   ( 09951-07100 )

    4. 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 (0.405 to 0.406 in.)
      Select a new exhaust valve guide bush (STD or O/S 0.05)
      Bush Size Bush Bore Diameter
      STD 10.285 to 10.306 mm (0.40492 to 0.40575 in.)
      O/S 0.05 10.335 to 10.356 mm (0.40689 to 0.40772 in.)

      If the exhaust valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.40575 in.), machine the exhaust valve guide bush bore of the cylinder head sub-assembly to a dimension of 10.335 to 10.356 mm (0.40689 to 0.40772 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 (0.40772 in.), replace the cylinder head sub-assembly.

    5. Heat the cylinder head sub-assembly to between 80 and 100°C (176 and 212°F).

      Note

      Be sure to wear protective gloves.

    6. A01R7EUC04
      *a Protrusion Height

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

      SST
      09201-10000   ( 09201-01050 )
      09950-70010   ( 09951-07100 )
      Standard Protrusion Height
      19.25 to 19.50 mm (0.758 to 0.768 in.)
    7. A01R542

      Using a sharp 5.5 mm reamer, ream the exhaust valve guide bush to obtain the standard 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. A01R75HC08
      *a Adhesive 1324
      *b Application Width
      *c Distance

      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.)
      Distance
      1.0 to 7.0 mm (0.0394 to 0.276 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 engine oil for at least 1 hour after installing it.

    2. A01R37TC02
      *a Protrusion Height

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

      Standard Protrusion Height
      112 mm (4.41 in.)

      Note

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

  4. REPLACE RING PIN

    Tech Tips

    It is not necessary to remove the ring pins unless they are being replaced.


    1. Remove the 2 ring pins.

    2. A01R76IC02
      *a Protrusion Height

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

      Standard Protrusion Height
      6.5 to 7.5 mm (0.256 to 0.295 in.)