Cylinder Head (W/O Glow Plug Controller) Replacement

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

1Kd-Ftv Engine Mechanical. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

REPLACE INTAKE VALVE GUIDE BUSH
REPLACE EXHAUST VALVE GUIDE BUSH
REPLACE RING PIN

Cylinder Head (W/O Glow Plug Controller) -- Replacement

1. REPLACE INTAKE VALVE GUIDE BUSH

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

Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Cylinder Head (W/O Glow Plug Controller) Replacement

Using SST and a hammer, tap out the valve guide bush.
SST
09201-10000(09201-01060)
09950-70010(09951-07100)

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

Select a new guide bush.
New Guide Bush:
Item
Specified Condition
Bush bore diameter
10.985 to 11.006 mm (0.432 to 0.433 in.)
11.035 to 11.056 mm (0.434 to 0.435 in.)
Bush to be used
STD
O/S 0.05
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.

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

Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Cylinder Head (W/O Glow Plug Controller) Replacement

Using SST and a hammer, tap in a new guide bush to the specified protrusion height.
SST
09201-10000(09201-01060)
09950-70010(09951-07100)
Standard protrusion height (H):
10.3 to 10.7 mm (0.406 to 0.421 in.)

Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Cylinder Head (W/O Glow Plug Controller) Replacement

Using a sharp 6.0 mm reamer, ream the guide bush to obtain the standard clearance between the guide bush and valve stem.
Standard clearance:
0.025 to 0.060 mm (0.00984 to 0.00236 in.)
Text in Illustration
*1
Sharp 6.0 mm Reamer

2. REPLACE EXHAUST VALVE GUIDE BUSH

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

Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Cylinder Head (W/O Glow Plug Controller) Replacement

Using SST and a hammer, tap out the valve guide bush.
SST
09201-10000(09201-01060)
09950-70010(09951-07100)

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

Select a new guide bush.
New Guide Bush:
Item
Specified Condition
Bush bore diameter
10.985 to 11.006 mm (0.4325 to 0.4333 in.)
11.035 to 11.056 mm (0.4344 to 0.4353 in.)
Bush to be used
STD
O/S 0.05
If the bush bore diameter of the cylinder head is more than 11.006 mm (0.4333 in.), machine the bush bore diameter to between 11.035 and 11.056 mm (0.4344 and 0.4353 in.).
If the bush bore diameter of the cylinder head is more than 11.056 mm (0.4353 in.), replace the cylinder head.

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

Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Cylinder Head (W/O Glow Plug Controller) Replacement

Using SST and a hammer, tap in a new guide bush to the specified protrusion height.
SST
09201-10000(09201-01060)
09950-70010(09951-07100)
Standard protrusion height (H):
10.3 to 10.7 mm (0.406 to 0.421 in.)

Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.1Kd-Ftv Engine Mechanical.Engine.Cylinder Head (W/O Glow Plug Controller) Replacement

Using a sharp 6.0 mm reamer, ream the guide bush to obtain the standard clearance between the guide bush and valve stem.
Standard clearance:
0.035 to 0.070 mm (0.00138 to 0.00276 in.)
Text in Illustration
*1
Sharp 6.0 mm Reamer

3. REPLACE RING PIN

HINT:

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

Remove the ring pin.

Using a plastic-faced hammer, tap in a new ring pin until the pin stops.
Standard protrusion:
Less than 5 mm (0.197 in.)

Text in Illustration
*a
Less than 5 mm (0.197 in.)
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