Replacement

1GR-FE 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.

Select a New Guide Bush:





If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 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 greater 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.

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 new intake valve guide bushes to the specified protrusion height.





Text in Illustration





SST : 09201-10000

09201-01050

SST : 09950-70010

09951-07100

Protrusion height:

9.10 to 9.90 mm (0.358 to 0.390 in.)

(i) Using a sharp 5.5 mm reamer, ream the valve guide bushings 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.

Select a 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 greater 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.

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:

9.10 to 9.90 mm (0.358 to 0.390 in.)

Text in Illustration





(i) Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.





Standard oil clearance:

0.030 to 0.065 mm (0.00118 to 0.00256 in.)

3. REPLACE UNION

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





Text in Illustration





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

Adhesive:

Toyota Genuine Seal Adhesive 1324, Three Bond 1324 or equivalent

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

Torque : 15 Nm (150 kgf-cm, 11 ft-lbf)

4. REPLACE TIGHT PLUG

HINT
If coolant leaks from a tight plug or a plug is corroded, replace it.

(a) Remove the tight plugs.

(b) Apply adhesive around new tight plugs.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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





Text in Illustration





SST : 09950-60010

09951-00250

SST : 09950-70010

09951-07150

Standard depth:

1.7 to 2.7 mm (0.0669 to 0.106 in.)

5. REPLACE STRAIGHT PIN

HINT
If a straight pin is deformed, replace it.

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





Text in Illustration





Protrusion height:

18.0 to 19.0 mm (0.708 to 0.748 in.)

6. REPLACE RING PIN

HINT
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.





Text in Illustration





Protrusion height:

2.5 to 3.5 mm (0.0984 to 0.138 in.)

7. REPLACE SPARK PLUG TUBE





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

(a) Remove the spark plug tube.

Text in Illustration





(b) 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:
* Be careful not to deform the spark plug tube.
* Be careful not to expose the seal to coolant for at least 1 hour after installing it.

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





Text in Illustration





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.