Prepare 4 new O/S pistons.

• Standard piston diameter:

• Item	Specified Condition
  O/S 0.50	99.950 to 99.980 mm (3.935 to 3.936 in.)

Using a micrometer, measure the piston diameter at right angles to the piston pin center line where the distance from the piston head is as specified.

• Standard distance:
• 61.27 to 61.33 mm (2.412 to 2.415 in.)

Calculate the amount each cylinder is to be rebored as follows.

• УКАЗАНИЕ:

Bore and hone the cylinders to the calculated dimensions.

• Maximum honing:
• 0.02 mm (0.000787 in.)

• ПРИМЕЧАНИЕ:

• Excess honing will destroy the finished roundness.

Install the stud bolts as shown in the illustration.

• Момент затяжки:
• 15 N*m{ 148 kgf*cm, 11 ft.*lbf}

Apply adhesive to 2 or 3 threads of the screw plug.

• Adhesive:
• Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the screw plug.

• Момент затяжки:
• 20 N*m{ 199 kgf*cm, 14 ft.*lbf}

Apply adhesive to 2 or 3 threads of the water drain cock.

• Adhesive:
• Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the water drain cock.

• Момент затяжки:
• 57 N*m{ 581 kgf*cm, 42 ft.*lbf}

• УКАЗАНИЕ:

Using a 6 mm hexagon socket wrench, install the oil orifice.

• Момент затяжки:
• 11 N*m{ 110 kgf*cm, 8 ft.*lbf}

Align the pin of the oil nozzle with the one of the pin holes of the cylinder block.

Install the oil nozzle with the check valve.

• Момент затяжки:
• 26 N*m{ 260 kgf*cm, 19 ft.*lbf}

Assemble the piston and connecting rod.

Using snap ring pliers, install a new snap ring on one side of the piston pin hole.

Gradually heat the piston to about 60°C (140°F).

Coat the piston pin with engine oil.

Align the front marks of the piston and connecting rod, connect the connecting rod to the piston, and then push in the piston pin with your thumb.

Text in Illustration

*1	Front Mark

Check the fitting condition between the piston and piston pin. Try to move the piston back and forth on the piston pin.

Using snap ring pliers, install a new snap ring on the other side of the piston pin hole.

Install the piston rings.

Install the coil and oil ring by hand.

Text in Illustration

*1	Coil Joint
*2	Oil Ring Ends

• УКАЗАНИЕ:

• Make sure the end gap of the oil ring faces the opposite direction of the coil joint.

Using a piston ring expander, install the No. 1 and No. 2 piston rings with the code mark facing upward.

• Code Mark:

• Item	Code Mark
  No. 1 piston ring	1N
  No. 2 piston ring	2N

Text in Illustration

*1	No. 1
*2	No. 2
*3	Code Mark

Position the piston rings so that the ring ends are as shown in the illustration.

Text in Illustration

*1	No. 1 Compression Ring
*2	No. 2 Compression Ring
*3	Oil Ring
*4	Coil
*5	Front Mark

• ПРИМЕЧАНИЕ:

• Do not align the ring ends.

Align the bearing claw with the groove of the connecting rod or connecting rod cap.

Install the bearings to the connecting rod and connecting rod cap.

Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings to install them.

Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings to install them.

Install the 2 thrust washers to the No. 3 journal position of the cylinder block with the oil grooves facing outward.

Install the 2 thrust washers to the No. 3 crankshaft bearing cap with the grooves facing outward.

Place the crankshaft on the cylinder block.

Install the 5 crankshaft bearing caps in their proper locations.

Install the crankshaft bearing cap bolts.

Apply a light coat of the engine oil to the threads and under the bolt heads of the crankshaft bearing caps.

Install and uniformly tighten the 10 bolts of the crankshaft bearing caps, in several steps, in the sequence shown in the illustration.

• Момент затяжки:
• 105 N*m{ 1071 kgf*cm, 77 ft.*lbf}

Check that the crankshaft turns smoothly.

Check the crankshaft thrust clearance (See page ).

Cover the connecting rod bolts with a short piece of hose to protect the crankshaft and cylinder bore from damage.

Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.

Place the connecting rod cap on the connecting rod.

Match each numbered connecting rod cap with the correct connecting rod.

Install the connection rod cap with the front mark facing forward.

Text in Illustration

*1	Front Mark

Install the connecting rod cap nuts.

• ПРИМЕЧАНИЕ:

• If any connecting rod bolt is broken or deformed, replace it.

• УКАЗАНИЕ:

• The connecting rod cap nuts are tightened in 2 progressive steps.

Apply a light of engine oil to the threads and under the heads of the connecting rod cap nuts.

Step 1:

Install and alternately tighten the nuts of the connecting rod cap in several passes.

• Момент затяжки:
• 54 N*m{ 551 kgf*cm, 40 ft.*lbf}

• УКАЗАНИЕ:

• If any one of the connecting rod cap nuts does not meet the torque specification, replace them.

Step 2:

Check that the painted marks are now at a 90° angle to the front.

Check that the crankshaft turns smoothly.

Check the connecting rod thrust clearance (See page ).

Apply adhesive to new tight plugs.

• Adhesive:
• Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the tight plugs as shown in the illustration.

Using SST, tap in the 2 tight plugs labeled A.

• SST
• 09950-60010(09951-00250)
  09950-70010(09951-07100)

Using SST, tap in the 4 tight plugs labeled B.

• SST
• 09950-60010(09951-00350)
  09950-70010(09951-07100)

Using SST, tap in the tight plug labeled C.

• SST
• 09950-60010(09951-00500)
  09950-70010(09951-07100)

Install the straight pins as shown in the illustration.

Install the ring pins as shown in the illustration.

Using SST and a press, press out the bushing.

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

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

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

• SST
• 09222-54011(09222-03021)

Align the oil holes of the bush and connecting rod.

Using SST and a press, press in the bush.

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

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

Check the piston pin fit at normal room temperature.

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

Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

Using a soft brush and solvent, thoroughly clean the cylinder block.

Inspect for flatness.

Using a precision straightedge and feeler gauge, measure the surfaces that contacts the cylinder head and main bearing cap for warpage.

• Maximum warpage:
• 0.20 mm (0.00787 in.)

If the warpage is more than the maximum, replace the cylinder block.

Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all 4 cylinders. If necessary, replace the cylinder block.

Inspect the cylinder bore diameter.

Text in Illustration

*1	No. 1
*2	No. 2
*3	No. 3
*4	No. 4
*5	Mark 1, 2 or 3
	Front

• УКАЗАНИЕ:

• There are 3 sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the lower left rear of the cylinder block.

Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.

• Standard Diameter:

• Item	Specified Condition
  Mark 1	99.500 to 99.510 mm (3.9173 to 3.9177 in.)
  Mark 2	99.510 to 99.520 mm (3.9177 to 3.9181 in.)
  Mark 3	99.520 to 99.530 mm (3.9181 to 3.9185 in.)

• Maximum Diameter:

• Item	Specified Condition
  STD	99.73 mm (3.93 in.)
  O/S 0.50	100.23 mm (3.95 in.)

Text in Illustration

*1	Thrust Direction
*2	Axial Direction
*3	Center
	Front

If the diameter is more than the maximum, rebore all cylinders. If necessary, replace the cylinder block.

Using a gasket scraper, remove the carbon from the piston top.

Using a groove cleaning tool or broken ring, clean the piston ring grooves.

Using solvent and a brush, thoroughly clean the piston.

• ПРИМЕЧАНИЕ:

• Do not use a wire brush.

Using a micrometer, measure the piston diameter at right angles to the piston center line where the distance from the piston head is as specified.

• Distance:
• 61.27 to 61.33 mm (2.41 to 2.42 in.)

• Standard Piston Diameter:

• Item	Specified Condition
  Mark 1	99.450 to 99.460 mm (3.9153 to 3.9157 in.)
  Mark 2	99.460 to 99.470 mm (3.9157 to 3.9161 in.)
  Mark 3	99.470 to 99.480 mm (3.9161 to 3.9165 in.)
  O/S 0.50	99.950 to 99.980 mm (3.935 to 3.936 in.)

Subtract the piston diameter measurement from the cylinder bore diameter measurement.

• Standard oil clearance:
• 0.040 to 0.060 mm (0.00157 to 0.00236 in.)

• Maximum oil clearance:
• 0.13 mm (0.00512 in.)

If the oil clearance is more than the maximum, replace all 4 pistons and rebore all 4 cylinders. If necessary, replace the cylinder block.

• УКАЗАНИЕ:

• Use a piston with the same number mark as the cylinder diameter marked on the cylinder block.

Inspect the piston pin fit.

Heat the piston to approximately. 60°C (140°F), and push the piston pin into the piston pin hole with your thumb.

If the pin can be installed at a lower temperature, replace the piston and pin as a set.

Using a micrometer, measure the piston pin diameter.

• Standard piston pin diameter:

• Item	Specified Condition
  Mark A	29.000 to 29.004 mm (1.1417 to 1.1419 in.)
  Mark B	29.004 to 29.008 mm (1.1419 to 1.1420 in.)
  Mark C	29.008 to 29.012 mm (1.1420 to 1.1422 in.)

Inspect the piston pin oil clearance.

Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

• Standard Groove Clearance:

• Item	Specified Condition
  No. 1 compression ring	0.057 to 0.101 mm (0.00224 to 0.00398 in.)
  No. 2 compression ring	0.060 to 0.100 mm (0.00236 to 0.00394 in.)
  Oil ring	0.030 to 0.070 mm (0.00118 to 0.00276 in.)

• Maximum groove clearance:
• 0.20 mm (0.00787 in.)

If the clearance is more than the maximum, replace the piston.

Insert the compression ring into the cylinder bore.

Using a piston, push the compression ring a little beyond the bottom of the ring travel, 140 mm (5.15 in.) from the top of the cylinder block.

Using a feeler gauge, measure the end gap.

• Standard End Gap:

• Item	Specified Condition
  No. 1 compression ring	0.350 to 0.470 mm (0.0138 to 0.0185 in.)
  No. 2 compression ring	0.470 to 0.600 mm (0.0185 to 0.0236 in.)
  Oil ring	0.200 to 0.400 mm (0.00787 to 0.0157 in.)

• Maximum End Gap:

• Item	Specified Condition
  No. 1 compression ring	1.29 mm (0.0508 in.)
  No. 2 compression ring	1.42 mm (0.0559 in.)
  Oil ring	1.22 mm (0.0480 in.)

If the end gap is more than the maximum, replace the compression ring.

If the end gap is more than the maximum even with a new compression ring, rebore all 4 cylinders or replace the cylinder block.

Using a rod aligner and feeler gauge, check the connecting rod alignment.

Check if the connecting rod is bent.

• Maximum bend:
• 0.05 mm (0.00196 in.) per 100 mm (3.94 in.)

If the bend is more than the maximum, replace the connecting rod.

Check if the connecting rod is twisted.

• Maximum twist:
• 0.15 mm (0.00591 in.) per 100 mm (3.94 in.)

If the twist is more than the maximum, replace the connecting rod.

Using a vernier caliper, measure the diameter of the tension portion of the connecting rod bolt.

• Standard diameter:
• 8.400 to 8.600 mm (0.331 to 0.339 in.)

• Minimum diameter:
• 8.20 mm (0.323 in.)

• Text in Illustration

  *1	Compressed Bolt

If the diameter is less than the minimum, replace the bolt.

Inspect for circle runout.

Inspect the main journals and crank pins.

Using a micrometer, measure the diameter of each main journal and crank pin.

• Standard Main Journal Diameter:
• 61.985 to 62.000 mm (2.4403 to 2.4409 in.)

• Standard Crank Pin Diameter:
• 54.988 to 55.000 mm (2.1649 to 2.1654 in.)

If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft.

Check each main journal and crank pin for taper and out of round as shown in the illustration.

• Maximum taper and out of round:
• 0.02 mm (0.000787 in.)

If the taper and out of round is more than the maximum, replace the crankshaft.

If necessary, grind and hone the main journals and/or crank pins.

Remove the crankshaft (See page ).

Clean each crankshaft journal and bearing.

Check each crankshaft journal and bearing for pitting and scratches.

If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.

Place the crankshaft on the cylinder block.

Lay a strip of Plastigage across each journal.

Install the 5 crankshaft bearing caps (See page ).

• ПРИМЕЧАНИЕ:

• Do not turn the crankshaft.

Remove the 10 bolts and 5 crankshaft bearing caps.

Measure the Plastigage at its widest point.

• Standard Oil Clearance:

• Item	Specified Condition
  STD	0.034 to 0.065 mm (0.00134 to 0.00256 in.)
  U/S 0.25, U/S 0.50	0.033 to 0.079 mm (0.00130 to 0.00311 in.)

• Maximum oil clearance:
• 0.10 mm (0.00394 in.)

If the oil clearance is more than the maximum, replace the bearings. If necessary, grind or replace the crankshaft.

If using a standard bearing, replace it with one having the same number marked on the connecting rod cap. There are 3 sizes of standard bearing, marked 1, 2 and 3 accordingly.

• Standard Sized Bearing Center Wall Thickness:

• Item	Specified Condition
  Mark 1	1.979 to 1.983 mm (0.0779 to 0.0781 in.)
  Mark 2	1.983 to 1.987 mm (0.0781 to 0.0782 in.)
  Mark 3	1.987 to 1.991 mm (0.0782 to 0.0784 in.)

Text in Illustration

*1	No. 1
*2	No. 2
*3	No. 3
*4	No. 4
*5	No. 5
*6	Mark 1, 2 or 3
	Front

Completely remove the Plastigage.

Perform the inspection above for each crank journal.

Lift out the crankshaft.

• УКАЗАНИЕ:

• Keep the upper crankshaft bearings and upper thrust washers together with the cylinder block.

Inspect the check valve.

Push the valve with a wooden stick to check if it is stuck.

If stuck, replace the check valve.

Inspect the oil nozzle

Check the oil nozzle for damage or clogging.

If necessary, replace the oil nozzle.

Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

• Standard thrust clearance:
• 0.080 to 0.300 mm (0.00315 to 0.0118 in.)

• Maximum thrust clearance:
• 0.35 mm (0.0138 in.)

If the thrust clearance is more than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.

Check the matchmarks on the connecting rod and cap to ensure correct reassembly.

Remove the 2 connecting rod cap nuts.

Using a plastic-faced hammer, lightly tap the connecting rod bolts and lift off the connecting rod cap.

• УКАЗАНИЕ:

• Keep the lower bearing installed to the connecting rod cap.

Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.

Clean the crank pin and bearing.

Check the crank pin and bearing for pitting and scratches.

If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.

Lay a strip of Plastigage across the crank pin.

Place the connecting rod cap on the connecting rod.

Match the numbered connecting rod cap with the connecting rod.

Install the connecting rod cap with the front mark facing forward.

Text in Illustration

*1	Front Mark

Install the connecting rod cap with the 2 nuts.

• УКАЗАНИЕ:

• The connecting rod cap nuts are tightened in 2 progressive steps.

• If any connecting rod bolt is broken or deformed replace it.

Apply a light of engine oil to the threads and under the heads of the connecting rod cap nuts.

Step 1:

Install and alternately tighten the nuts of the connecting rod cap in several passes.

• Момент затяжки:
• 54 N*m{ 551 kgf*cm, 40 ft.*lbf}

• ПРИМЕЧАНИЕ:

• Do not turn the crankshaft.

Step 2:

Check that the painted marks are now at a 90° angle to the front.

Remove the 2 nuts, connecting rod cap and lower bearing.

Measure the Plastigage at its widest point.

• Standard Oil Clearance:

• Item	Specified Condition
  STD	0.036 to 0.064 mm (0.00142 to 0.00252 in.)
  U/S 0.25, U/S 0.50	0.033 to 0.079 mm (0.00130 to 0.00311 in.)

• Maximum oil clearance:
• 0.10 mm (0.00394 in.)

If the oil clearance is more than the maximum, replace the bearings. If necessary, grind or replace the crankshaft.

If using a standard bearing, replace it with one having the same number marked on the connecting rod cap. There are 3 sizes of standard bearings, marked 1, 2 and 3 accordingly.

• Standard Sized Bearing Center Wall Thickness:

• Item	Specified Condition
  Mark 1	1.478 to 1.482 mm (0.0582 to 0.0583 in.)
  Mark 2	1.482 to 1.486 mm (0.0583 to 0.0585 in.)
  Mark 3	1.486 to 1.490 mm (0.0585 to 0.0587 in.)

Completely remove the Plastigage.

Perform the inspection above for each crank pin.

Using a ridge reamer, remove all the carbon from the top of the cylinder.

Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.

Push the piston, connecting rod and upper bearing out through the top of the cylinder block.

• УКАЗАНИЕ:

Check the fitting condition between the piston and piston pin.

Using a piston ring expander, remove the 2 piston rings.

• УКАЗАНИЕ:

• Be sure to organize the removed piston rings in such a way that they can reinstalled exactly as before.

Remove the oil ring and coil by hand.

• УКАЗАНИЕ:

• Arrange the piston rings in the correct order.

Disconnect the connecting rod from the piston.

Using snap ring pliers, remove the 2 snap rings from the piston.

Gradually heat the piston to approximately 60°C (140°F).

Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.

• УКАЗАНИЕ:

The piston and pin are a matched set.

Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

• Standard thrust clearance:
• 0.040 to 0.250 mm (0.00157 to 0.00984 in.)

• Maximum thrust clearance:
• 0.30 mm (0.0118 in.)

If the thrust clearance is more than the maximum, replace the thrust washers as a set.

• Thrust Washer Thickness:

• Item	Specified Condition
  STD	2.430 to 2.480 mm (0.0957 to 0.0976 in.)
  O/S 0.125	2.493 to 2.543 mm (0.0981 to 0.100 in.)
  O/S 0.250	2.555 to 2.605 mm (0.101 to 0.103 in.)

Uniformly loosen and remove the 10 crankshaft bearing cap bolts in several passes, in the sequence shown.

Using the removed crankshaft bearing cap bolts, pry the cap back and forth, and remove the crankshaft bearing caps, lower bearings and lower thrust washers (No. 3 crankshaft bearing cap only).

• УКАЗАНИЕ:

Remove the crankshaft.

Remove the 4 check valves and oil nozzles.

Using a 6 mm hexagon socket wrench, remove the oil orifice.

Remove the water drain cock from the cylinder block.

Check the valve seating position.

If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.

If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.

Hand-lap the valve and valve seat with an abrasive compound.

Clean the valve and valve seat.

Check the valve seating position.

If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.

If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.

Hand-lap the valve and valve seat with an abrasive compound.

Clean the valve and valve seat.

Remove any old packing (FIPG material).

Apply seal packing to the semicircular plug as shown in the illustration.

• Seal packing:
• Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

• ПРИМЕЧАНИЕ:

Install the semicircular plug to the cylinder head.

Select the number of shim, according to the table below.

• Select a new combustion chamber:

• Item	Specified Condition
  Mark 1	5.91 to 5.94 mm (0.2327 to 0.2338 in.)
  Mark 2	5.94 to 5.97 mm (0.2338 to 0.2350 in.)
  Mark 3	5.97 to 6.00 mm (0.2350 to 0.2362 in.)

Text in Illustration

*1	No. 1 Combustion Chamber
*2	No. 2 Combustion Chamber
*3	No. 3 Combustion Chamber
*4	No. 4 Combustion Chamber
*5	Mark 1, 2 or 3
	Front

Align the combustion chamber knock pin with the cylinder head notch.

Using a plastic-faced hammer, tap in the combustion chamber.

Using a dial indicator, check the combustion chamber protrusion.

• Combustion chamber protrusion:
• -0.03 to 0.03 mm (- 0.00118 to 0.00118 in.)

If the protrusion is less than the specification, adjust with shims.

If the protrusion is more than the specification, replace the chamber and recheck the protrusion.

Using SST, push in a new oil seal.

• SST
• 09201-41020

Install the valve, spring seat plate washer, valve spring and spring retainer.

Using SST, compress the valve spring and place the 2 retainer locks around the valve stem.

• SST
• 09202-70020(09202-00030)

Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

• ПРИМЕЧАНИЕ:

• Be careful not to damage the valve stem tip.

Install the valve, spring seat, valve spring and spring retainer.

Using SST, compress the valve spring and place the 2 retainer locks around the valve stem.

• SST
• 09202-70020(09202-00030)

Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

• ПРИМЕЧАНИЕ:

• Be careful not to damage the valve stem tip.

Install the valve lifter and shim.

Check that the valve lifter rotates smoothly by hand.

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

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

• SST
• 09201-10000(09201-01080)
  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 Conditions
  Bush Bore Diameter	13.004 to 13.025 mm (0.512 to 0.513 in.)	13.054 to 13.075 mm (0.514 to 0.515 in.)
  Bush to be Used	STD	O/S 0.05

If the bush bore diameter of the cylinder head is more than 13.025 mm (0.513 in.), machine the bush bore to a dimension of 13.054 to 13.075 mm (0.514 to 0.515 in.).

If the bush bore diameter of the cylinder head is more than 13.075 mm (0.515 in.), replace the cylinder head.

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

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

• SST
• 09950-70010(09951-07100)
  09201-10000(09201-01070)

• Standard protrusion height:
• 10.8 to 11.2 mm (0.425 to 0.441 in.)

Using a sharp 8.0 mm reamer, ream the guide bush to obtain the specified clearance (See page ).

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

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

• SST
• 09201-10000(09201-01080)
  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 Conditions
  Bush Bore Diameter	13.004 to 13.025 mm (0.512 to 0.513 in.)	13.054 to 13.075 mm (0.514 to 0.515 in.)
  Bush to be Used	STD	O/S 0.05

If the bush bore diameter of the cylinder head is more than 13.025 mm (0.513 in.), machine the bush bore to a dimension of 13.054 to 13.075 mm (0.514 to 0.515 in.).

If the bush bore diameter of the cylinder head is more than 13.075 mm (0.515 in.), replace the cylinder head.

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

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

• SST
• 09950-70010(09951-07100)
  09201-10000(09201-01070)

• Standard protrusion height:
• 10.8 mm to 11.2 mm (0.425 to 0.441 in.)

Using a sharp 8.0 mm reamer, ream the guide bush to obtain the specified clearance (See page ).

Apply adhesive to new tight plugs.

• Adhesive:
• Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

Install the tight plugs as shown in the illustration.

Using SST, tap in the 7 tight plugs labeled A.

• SST
• 09950-60010(09951-00250)
  09950-70010(09951-07100)

Using SST, tap in the tight plug labeled B.

• SST
• 09950-60010(09951-00300)
  09950-70010(09951-07100)

Using SST, tap in the 2 tight plugs labeled C.

• SST
• 09950-60010(09951-00450)
  09950-70010(09951-07100)

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

• Standard Ring Pin:

• Item	Height	Diameter
  Ring pin	8 mm (0.315 in.)	11 mm (0.433 in.)

Clean the cylinder head.

Using a wire brush, remove all the carbon from the combustion chambers.

• ПРИМЕЧАНИЕ:

• Do not scratch the surface that contacts the cylinder block.

Using a valve guide bushing brush and solvent, clean all the guide bushes.

Using a soft brush and solvent, thoroughly clean the cylinder head.

Inspect the cylinder head warpage.

Inspect the cylinder head for cracks.

Using a gasket scraper, chip off any carbon from the valve head.

Using a wire brush, thoroughly clean the valve.

Using a micrometer, measure the diameter of the valve stem.

• Standard valve stem diameter:
• 7.975 to 7.990 mm (0.3140 to 0.3146 in.)

If the diameter is not as specified, replace the intake valve.

Check the valve face angle.

Check the head margin thickness.

• Standard margin thickness:
• 1.6 mm (0.0630 in.)

• Minimum margin thickness:
• 1.1 mm (0.0433 in.)

If the margin thickness is less than the minimum, replace the intake valve.

Check the overall length of the valve.

• Standard overall length:
• 104.10 to 104.50 mm (4.10 to 4.11 in.)

• Minimum overall length:
• 103.60 mm (4.08 in.)

If the overall length is less than the minimum, replace the intake valve.

Check the surface of the valve stem tip for wear.

If the valve stem tip is worn, resurface the tip with a grinder or replace the intake valve.

• ПРИМЕЧАНИЕ:

• Do not grind the valve so it becomes shorter than the minimum overall length.

Using a micrometer, measure the diameter of the valve stem.

• Standard valve stem diameter:
• 7.960 to 7.975 mm (0.3134 to 0.3140 in.)

If the diameter is not as specified, replace the exhaust valve.

Check the valve face angle.

Check the valve head margin thickness.

• Standard margin thickness:
• 1.7 mm (0.0669 in.)

• Minimum margin thickness:
• 1.2 mm (0.0472 in.)

If the margin thickness is less than the minimum, replace the exhaust valve.

Check the overall length of the valve.

• Standard overall length:
• 103.95 to 104.35 mm (4.09 to 4.11 in.)

• Minimum overall length:
• 103.45 mm (4.07 in.)

If the overall length is less than the minimum, replace the exhaust valve.

Check the surface of the valve stem tip for wear.

If the valve stem tip is worn, resurface the tip with a grinder or replace the exhaust valve.

• ПРИМЕЧАНИЕ:

• Do not grind the valve so it becomes shorter than the minimum overall length.

Using a steel square, measure the deviation of the spring.

• Maximum deviation:
• 2.0 mm (0.0787 in.)

If the deviation is more than the maximum, replace the spring.

Using a vernier caliper, measure the free length of the spring.

• Standard Free Length:
• 46.20 mm (1.82 in.)

If the free length is not as specified, replace the spring.

Using a spring tester, measure the tension of the valve spring at the installed length.

• Standard tension:
• 301 to 332 N (31 to 34 kgf, 66.6 to 74.6 lbf) at 37.00 mm (1.46 in.)

If the tension is not as specified, replace the spring.

Using a caliper gauge, measure the inside diameter of the guide bush.

• Standard bush inside diameter:
• 8.010 to 8.030 mm (0.315 to 0.316 in.)

Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.

• Standard oil clearance:
• 0.020 to 0.055 mm (0.000787 to 0.00217 in.)

• Maximum oil clearance:
• 0.08 mm (0.00315 in.)

If the clearance is more than the maximum, replace the intake valve and guide bush.

Using a caliper gauge, measure the inside diameter of the guide bush.

• Standard bush inside diameter:
• 8.010 to 8.030 mm (0.315 to 0.316 in.)

Subtract the valve stem diameter measurement from the guide bush inside diameter measurement.

• Standard oil clearance:
• 0.035 to 0.070 mm (0.00138 to 0.00276 in.)

• Maximum oil clearance:
• 0.10 mm (0.00394 in.)

If the clearance is more than the maximum, replace the exhaust valve and guide bush.

Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.

Check the valve seating position.

Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.

Check the valve seating position.

Using a micrometer, measure the lifter diameter.

• Standard lifter diameter:
• 40.892 to 40.902 mm (1.6099 to 1.6103 in.)

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

• Standard lifter bore diameter:
• 40.960 to 40.980 mm (1.6126 to 1.6134 in.)

Subtract the lifter diameter measurement from the lifter bore diameter measurement.

• Standard oil clearance:
• 0.058 to 0.088 mm (0.00238 to 0.00346 in.)

• Maximum oil clearance:
• 0.10 mm (0.00394 in.)

If the oil clearance is more than the maximum, replace the lifter. If necessary, replace the cylinder head.

Inspect the journal diameter of the camshaft.

Check the oil clearance.

Clean the bearing caps and journals.

Check the bearings for flaking and scoring.

If the bearings are damaged, replace the bearing caps and cylinder head as a set.

Install the bearings to the bearing caps and cylinder head.

Place the camshaft on the cylinder head.

Lay a strip of Plastigage across each of the journals.

Text in Illustration

*1	Plastigage

Install the bearing caps (See page ).

• ПРИМЕЧАНИЕ:

• Do not turn the camshaft.

Remove the bearing caps (See page ).

Measure the Plastigage at its widest point.

• Standard oil clearance:
• 0.022 to 0.074 mm (0.000866 to 0.00291 in.)

• Maximum oil clearance:
• 0.10 mm (0.00394 in.)

Text in Illustration

*1	Plastigage

If the oil clearance is more than the maximum, replace the cylinder head sub-assembly. If necessary, grind or replace the camshaft.

Completely remove the Plastigage.

Remove the camshaft.

Check the thrust clearance.

Install the camshaft.

Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

• Standard thrust clearance:
• 0.080 to 0.280 mm (0.00351 to 0.0110 in.)

• Maximum thrust clearance:
• 0.35 mm (0.0138 in.)

If the thrust clearance is more than the maximum, replace the No. 1 bearing. If necessary, replace the camshaft.