Replacement

2GR-FXE ENGINE MECHANICAL: CYLINDER HEAD: REPLACEMENT

1. REPLACE INTAKE VALVE GUIDE BUSH

(a) Heat the cylinder head to 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 intake valve guide bushes.

SST : 09201-10000

09201-01050

SST : 09950-70010

09951-07100

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

Standard Bush Bore Diameter:

(e) Select a new valve guide bush.

New Guide Bush:

If the bush bore diameter of the cylinder head is more than 10.306 mm (0.4057 in.), machine the bush bore diameter to 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install an O/S 0.05 valve guide bush.

If the bush bore diameter of the cylinder head is more than 10.356 mm (0.4077 in.), replace the cylinder head.

New Guide Bush Diameter:

HINT
Different bushes are used for the intake and exhaust valves.

Standard bush length:

41.3 to 41.7 mm (1.63 to 1.64 in.)

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

(g) Place the cylinder head on wooden blocks.

(h) Using SST, tap in the intake valve guide bushes to the specified protrusion height.

SST : 09201-10000

09201-01050

SST : 09950-70010

09951-07100

Protrusion height:

9.30 to 9.70 mm (0.366 to 0.382 in.)

Text in Illustration

(i) 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.)

2. REPLACE EXHAUST VALVE GUIDE BUSH

(a) Heat the cylinder head to 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 exhaust valve guide bushes.

SST : 09201-10000

09201-01050

SST : 09950-70010

09951-07100

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

Standard Bush Bore Diameter:

(e) Select a new valve guide bush.

New Guide Bush:

HINT
Different bushes are used for the intake and exhaust valves.

Standard bush length:

46.8 to 47.2 mm (1.84 to 1.86 in.)

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

(g) Place the cylinder head on wooden blocks.

(h) Using SST, tap in the exhaust valve guide bushes to the specified protrusion height.

SST : 09201-10000

09201-01050

SST : 09950-70010

09951-07100

Protrusion height:

9.30 to 9.70 mm (0.366 to 0.382 in.)

Text in Illustration

(i) 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.)

3. REPLACE RING PIN

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

(a) Using a plastic-faced hammer, tap in new ring pins to the specified protrusion height.

Specified protrusion height:

2.5 to 3.5 mm (0.0984 to 0.138 in.)

Text in Illustration

4. REPLACE STRAIGHT PIN

NOTICE:
If a straight pin is deformed, replace it.

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

Protrusion height:

18.0 to 19.0 mm (0.709 to 0.748 in.)

Text in Illustration

5. REPLACE SPARK PLUG TUBE

HINT
When using a new cylinder head, the spark plug tubes must be replaced.

(a) Apply adhesive to the shaded area of a new spark plug tube.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

Standard application width:

1.0 to 3.0 mm (0.0394 to 0.118 in.)

Text in Illustration

NOTICE:
* Install the spark plug tube within 3 minutes after applying adhesive.
* Be careful not to deform the spark plug tube.
* Be careful not to expose the seal to engine oil for at least 1 hour after installation.

(b) Using a wooden block and hammer, tap in the spark plug tube to the specified protrusion height.

Standard protrusion height:

72.9 mm (2.87 in.)

Text in Illustration

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