Cylinder Head Replacement

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

Place the cylinder head on wooden blocks.

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

SST

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

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.)

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

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.)

HINT:

Different bushes are used for the intake and exhaust.

Standard bush length:

41.3 to 41.7 mm (1.63 to 1.64 in.)

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

Place the cylinder head on wooden blocks.

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.)

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.)

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

Place the cylinder head on wooden blocks.

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

SST

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

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.)

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

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.)

HINT:

Different bushes are used for the intake and exhaust.

Standard bush length:

46.8 to 47.2 mm (1.84 to 1.86 in.)

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

Place the cylinder head on wooden blocks.

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.)

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.)

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

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

Torque:

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

Remove the tight plugs.

Apply adhesive around new tight plugs.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

SST

09950-60010(09951-00250)
09950-70010(09951-07150)

Standard depth:

1.7 to 2.7 mm (0.0669 to 0.106 in.)

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

Protrusion height:

18.0 to 19.0 mm (0.708 to 0.748 in.)

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.)

Remove the spark plug tube.

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.)

NOTICE:

1. Be careful not to deform the spark plug tube.
   
2. Be careful not to expose the seal to coolant for at least 1 hour after installing it.
   

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.)

NOTICE:

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