Replacement

2GR-FSE ENGINE MECHANICAL: ENGINE UNIT: REPLACEMENT

1. REPLACE SPARK PLUG TUBE GASKET

(a) Pry up the claws of the ventilation baffle plate.

(b) Using a screwdriver with its tip taped and hammer, tap out the 6 spark plug tube gaskets.

NOTICE:
* Keep the lip free from foreign matter.
* Do not tap on the oil seal at an angle.

(d) Return the claws of the ventilation baffle plate to their original positions.

2. REPLACE ENGINE REAR OIL SEAL

(a) Place the oil seal retainer on wooden blocks.

(b) Using a screwdriver and hammer, tap out the oil seal.

(c) Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.

SST : 09223-15030

NOTICE:
* Keep the lip free from foreign matter.
* Do not tap on the oil seal at an angle.

3. REPLACE CONNECTING ROD SMALL END BUSH

(a) Using SST and a press, push out the bush.

SST : 09222-30010

(b) Align the oil holes of a new bush and the connecting rod.

SST : 09222-30010

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

Standard oil clearance:

-0.002 to 0.004 mm (-0.00007 to 0.0001 in.)

(e) Coat the piston pin with engine oil. Push the piston pin into the connecting rod with your thumb to check that the piston pin fits at normal room temperature.

4. REPLACE INTAKE VALVE GUIDE BUSH

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

(b) Place the cylinder head on wooden blocks.

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

SST : 09201-10000

09201-01050

SST : 09950-70010

09951-07100

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

Standard cylinder bore diameter:

10.285 to 10.306 mm (0.4049 to 0.4057 in.)

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

Standard bush bore diameter:

HINT
* If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore diameter to between 10.335 to 10.356 mm (0.4069 to 0.4077 in.).
* If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

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

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

SST : 09201-10000

09201-01050

SST : 09950-70010

09951-07100

Standard protrusion height:

9.3 to 9.7 mm (0.3662 to 0.3818)

(h) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem.

5. REPLACE EXHAUST VALVE GUIDE BUSH

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

(b) Place the cylinder head on wooden blocks.

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

SST : 09201-10000

09201-01050

SST : 09950-70010

09951-07100

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

Standard cylinder bore diameter:

10.285 to 10.306 mm (0.4049 to 0.4057 in.)

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

Standard bush bore diameter:

6. REPLACE CYLINDER BLOCK TIGHT PLUG

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

(a) Remove the tight plugs.

(b) Apply adhesive around the new tight plugs.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Using SST and a hammer, tap in the 3 tight plugs shown in the illustration.

SST : 09950-60010

09951-00340

SST : 09950-70010

09951-07100

7. REPLACE CYLINDER BLOCK STUD BOLT

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

(a) Remove the stud bolts.

(b) Using an E8 "TORX" socket wrench, install the stud bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

8. REPLACE CYLINDER BLOCK STRAIGHT PIN

NOTICE:
It is not necessary to remove the straight pin unless it is being replaced.

(a) Remove the straight pins.

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

Standard protrusion:

9. REPLACE CYLINDER HEAD RING PIN

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

(a) Remove the ring pins.

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

10. REPLACE CYLINDER HEAD STUD BOLT

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

(a) Remove the stud bolts.

(b) Using E6 and E8 "TORX" socket wrenches, install the stud bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) for stud bolts A, B and C

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) for stud bolt D

11. REPLACE CYLINDER HEAD SET STRAIGHT PIN

NOTICE:
It is not necessary to remove the straight pin unless it is being replaced.

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

Standard protrusion height:

17.5 to 19.5 mm (0.689 to 0.768 in.)

12. INSTALL UNION

(a) Apply adhesive to the union of the cylinder head.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Using SST, install the union to the cylinder head as shown in the illustration.