Engine unit 2AD-FHV Replacement

Engine unit 2AD-FHV
Replacement

1. Using SST and a press, push out the bush.

   SST:

   09222-54011 (09222-03016, 09222-03026)

2. Using a round file, lightly file off any roughness from the small end of the connecting rod.

3. Attach a new bush to SST with the ball of SST inside the oil hole of the bush.

   SST:

   09222-54011 (09222-03021)

4. Align the oil holes of the bush and connecting rod.

5. Using SST and a press, push in the bush.

   SST:

   09222-54011 (09222-03016, 09222-03026, 09222-03021)

6. Using a pin hole grinder, hone the bush to obtain the standard specified clearance between the bush and piston pin.

7. Check that the piston pin fits at normal room temperature.

   

   1. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

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

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

   SST:

   09201-10000 09950-70010

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

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

   Bush bore diameter:

   Bush size	Specified Condition
   Use STD	10.985 to 11.006 mm (0.4324 to 0.4333 in.)
   Use O/S 0.05	11.056 to 11.065 mm (0.4353 to 0.4356 in.)

   HINT:

   1. If the bush bore diameter of the cylinder head is greater than 11.006 mm (0.4333 in.), machine the bush bore diameter to between 11.056 and 11.065 mm (0.4353 to 0.4356 in.).
   2. If the bush bore diameter of the cylinder head is greater than 11.065 mm (0.4356 in.), replace the cylinder head.

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

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

   SST:

   09201-10000 09950-70010

   Standard protrusion height (H):

   9.0 to 9.4 mm (0.354 to 0.370 in.)

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

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

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

   SST:

   09201-10000 09950-70010

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

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

   Standard bush bore diameter:

   Bush Size	Specified Condition
   Use STD	11.006 to 11.015 mm (0.4333 to 0.4337 in.)
   Use O/S 0.05	11.056 to 11.065 mm (0.4353 to 0.4356 in.)

   HINT:

   1. If the bush bore diameter of the cylinder head is greater than 11.015 mm (0.4337 in.), machine the bush bore diameter to between 11.056 and 11.065 mm (0.4353 to 0.4356 in.).
   2. If the bush bore diameter of the cylinder head is greater than 11.065 mm (0.4356 in.), replace the cylinder head.

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

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

   SST:

   09201-10000 09950-70010

   Standard protrusion height (H):

   10.3 to 10.7 mm (0.406 to 0.421 in.)

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

NOTICE:

If water leaks from the tight plug or the plug corrodes, replace it.

1. Remove the tight plugs.

2. Apply adhesive around the tight plug.

   Adhesive:

   Toyota genuine adhesive 1324, three bond 1324 or equivalent

3. Using SST and a hammer, tap in 3 new tight plugs shown in the illustration.

   SST:

   09950-60010 09950-70010

   

NOTICE:

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

1. Remove the stud bolts.

2. Using an E5 "torx" socket wrench, install stud bolts A and C.

   Torque:

   3.0 N*m{ 31 kgf*cm , 27 lbsf.in } for bolt A

   2.0 N*m{ 20 kgf*cm , 18 lbsf.in } for bolt C

3. Apply adhesive to the hole for stud bolt B on the cylinder block. Install stud bolts B.

   Torque:

   20 N*m{ 204 kgf*cm , 15 ft.*lbf }

   

4. Apply adhesive to the hole for the stud bolt on the cylinder block. Install the 2 stud bolts to the crankshaft bearing cap.

   Torque:

   5.0 N*m{ 51 kgf*cm , 44 lbsf.in }

NOTICE:

It is not necessary to remove with straight pin unless it is being replaced.

1. Remove the straight pin.

2. Using a plastic-faced hammer, tap in new straight pins to the cylinder block.

   

3. Using a plastic-faced hammer, tap in new ring pins to the crankshaft bearing cap.

NOTICE:

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

1. Remove the ring pins.

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

   

NOTICE:

If water leaks from the tight plug or the plug corrodes, replace it.

1. Remove the tight plugs.

2. Apply adhesive to the tight plug hole of the cylinder head.

   Adhesive:

   Toyota genuine adhesive 1324, three bond 1324 or equivalent

3. Using SST, tap in a new tight plug to the cylinder head as shown in the illustration.

   SST:

   09950-60010 09950-70010

NOTICE:

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

1. Remove the stud bolts.

2. Using an E8 "torx" socket wrench, install the stud bolts.

   Torque:

   12 N*m{ 122 kgf*cm , 9 ft.*lbf } for stud bolt A and B

   5.0 N*m{ 51 kgf*cm , 44 lbsf.in } for stud bolt C

   8.0 N*m{ 82 kgf*cm , 71 lbsf.in } for stud bolt D