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CYLINDER HEAD REPLACEMENT

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  1. Click here

    REPLACE INTAKE VALVE GUIDE BUSH


    1. A01ISI7

      Gradually heat the cylinder head to 80 to 100°C (176 to 212°F).

    2. Place the cylinder head on a wooden block.

    3. A01IRBJE01

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

      09201-10000
      09950-70010
    4. A01IO3DE01

      Using a caliper gauge, measure the bush bore diameter of the cylinder head.

      If the bush bore diameter of the cylinder head is more than 11.006 mm (0.433 in.), machine the bush bore diameter to between 11.035 and 11.056 mm (0.434 and 0.435 in.).

      If the bush bore diameter of the cylinder head is more than 11.056 mm (0.435 in.), replace the cylinder head.

    5. Select a new guide bush (STD or O/S 0.05).

      Guide Bush
      Bush Size Specified Condition
      Use STD 10.985 to 11.006 mm (0.432 to 0.433 in.)
      Use O/S 0.05 11.035 to 11.056 mm (0.434 to 0.435 in.)
    6. A01ISI7

      Gradually heat the cylinder head to 80 to 100°C (176 to 212°F).

    7. Place the cylinder head on a wooden block.

    8. A01IRQTE02

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

      09201-10000
      09950-70010
      Standard protrusion height (H)
      9.0 to 9.4 mm (0.354 to 0.370 in.)
    9. A01IR2CE02

      Using a sharp 6.0 mm reamer, ream the valve guide bush to obtain the standard specified clearance between the valve guide bush and valve stem.

      Table 1. Text in Illustration
      *1 Sharp 6.0 mm Reamer
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    REPLACE EXHAUST VALVE GUIDE BUSH


    1. A01ISI7

      Gradually heat the cylinder head to 80 to 100°C (176 to 212°F).

    2. Place the cylinder head on a wooden block.

    3. A01IP3ZE01

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

      09201-10000
      09950-70010
    4. A01IO3DE01

      Using a caliper gauge, measure the bush bore diameter of the cylinder head.

      If the bush bore diameter of the cylinder head is more than 11.006 mm (0.433 in.), machine the bush bore diameter to between 11.035 and 11.056 mm (0.434 and 0.435 in.).

      If the bush bore diameter of the cylinder head is more than 11.056 mm (0.435 in.), replace the cylinder head.

    5. Select a new guide bush (STD or O/S 0.05).

      Guide Bush
      Bush Size Specified Condition
      Use STD 10.985 to 11.006 mm (0.432 to 0.433 in.)
      Use O/S 0.05 11.035 to 11.056 mm (0.434 to 0.435 in.)
    6. A01ISI7

      Gradually heat the cylinder head to 80 to 100°C (176 to 212°F).

    7. Place the cylinder head on a wooden block.

    8. A01IQQ0E01

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

      09201-10000
      09950-70010
      Standard protrusion height (H)
      9.0 to 9.4 mm (0.354 to 0.370 in.)
    9. A01IR2CE02

      Using a sharp 6.0 mm reamer, ream the valve guide bush to obtain the standard specified clearance between the valve guide bush and valve stem.

      Table 2. Text in Illustration
      *1 Sharp 6.0 mm Reamer
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    REPLACE CYLINDER HEAD RING PIN

    Tip:

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


    1. Remove the ring pin.

    2. A01ITKXE01

      Using a plastic-faced hammer, tap in a new ring pin until the pin stops.

      Standard Protrusion
      Item Specified Condition
      Pin A 3.9 to 5.5 mm (0.154 to 0.217 in.)
      Pin B 2.5 to 3.5 mm (0.0984 to 0.138 in.)
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    REPLACE NO. 1 STRAIGHT SCREW PLUG WITH HEAD


    1. A01IO0I

      Using a 6 mm hexagon wrench, remove the straight screw plugs.

    2. Apply adhesive to new straight screw plugs.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Using a 6 mm hexagon wrench, install the straight screw plugs.

      25 N*m 255 kgf*cm 18 ft.*lbf
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    REPLACE CYLINDER HEAD STUD BOLT

    Tip:

    If a stud bolt is deformed or the threads are damaged, replace it.


    1. Remove the stud bolts.

    2. A01IOZKE01

      Using an E8 "TORX" socket wrench, install new stud bolts.

      for stud bolt A and B
      12 N*m 122 kgf*cm 9 ft.*lbf
      for stud bolt C
      5.0 N*m 51 kgf*cm 44 in.*lbf
      for stud bolt D
      8.0 N*m 82 kgf*cm 71 in.*lbf