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Engine Unit: Replacement

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  1. REMOVE SPARK PLUG TUBE GASKET 
    1. Pry up the claws of the ventilation baffle plate.
      Fig 1: Identifying Claws Of Ventilation Baffle Plate
      G04996852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver with its tip taped and a hammer, tap out the 3 spark plug tube gaskets.
      Fig 2: Tapping Out Spark Plug Tube Gaskets
      G04996853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE ENGINE REAR OIL SEAL 
    1. Place the oil seal retainer on wooden blocks.
    2. Using a screwdriver and a hammer, tap out the oil seal.

      HINT:

      Tape the screwdriver tip before use.

      Fig 3: Tapping Out Oil Seal
      G04996854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE TIMING CHAIN COVER OIL SEAL 
    1. Using a screwdriver, pry out the oil seal.

      HINT:

      Tape the screwdriver tip before use.

      Fig 4: Prying Out Oil Seal
      G04996855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL TIMING CHAIN COVER OIL SEAL 
    1. Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.

      SST 09316-60011 (09316-00011) 

      NOTE:
      • Keep the lip free from foreign matter.
      • Do not tap on the oil seal at an angle.
      • Make sure that the oil seal edge dose not stick out of the timing chain case.
        Fig 5: Tapping Oil Seal
        G04996856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL ENGINE REAR OIL SEAL 
    1. Place the oil seal retainer on wooden blocks.
    2. Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.

      SST 09223-15030 

      NOTE:
      • Keep the lip free from foreign matter.
      • Do not tap on the oil seal at an angle.
        Fig 6: Tapping Oil Seal
        G04996857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL SPARK PLUG TUBE GASKET 
    1. Using a 32 mm socket wrench, tap in 6 new spark plug tube gaskets to the head covers.
      NOTE:
      • Keep the lip free from foreign matter.
      • Do not tap on the oil seal at an angle.
    2. Return the claw of the ventilation baffle plate to its original position.
      Fig 7: Tapping Spark Plug Tube Gaskets To Head Covers
      G04996858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE INTAKE VALVE GUIDE BUSH 
    1. Heat the cylinder head to 80 to 100°C (176 to 212°F).
    2. Place the cylinder head on wooden blocks.
    3. Using SST and a hammer, tap out the guide bush.

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

      Fig 8: Tapping Out Guide Bush
      G04996859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE EXHAUST VALVE GUIDE BUSH 
    1. Heat the cylinder head to 80 to 100°C (176 to 212°F).
    2. Place the cylinder head on wooden blocks.
    3. Using SST and a hammer, tap out the guide bush.

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

      Fig 9: Tapping Out Guide Bush
      G04996860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL INTAKE VALVE GUIDE BUSH 
    1. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

      Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) 

    2. Select a new guide bush (STD or O/S 0.05).
      GUIDE BUSH SPECIFICATION

      Bush size Bush bore diameter
      Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
      Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
      Fig 10: Measuring Bush Bore Diameter Of Cylinder Head
      G04996861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 a 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.

    3. Heat the cylinder head to 80 to 100°C (176 to 212°F)
    4. Place the cylinder head on wooden blocks.
    5. Using SST, tap in a new valve guide bush to the specified protrusion height.

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

      Protrusion height: 9.30 to 9.70 mm (0.3661 to 0.3819 in.) 

      Fig 11: Tapping Valve Guide Bush To Specified Protrusion Height
      G04996862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a sharp 5.5 mm reamer, ream the valve guide bush to obtain the standard specified clearance.

      Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0023 in.) 

      Fig 12: Reaming Valve Guide Bush
      G04974762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL EXHAUST VALVE GUIDE BUSH 
    1. Using a caliper gauge, measure the bush bore diameter of the cylinder head.

      Cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) 

    2. Select a new guide bush (STD or O/S 0.05).
      GUIDE BUSH SPECIFICATION

      Bush size Bush bore diameter
      Use STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
      Use O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
      Fig 13: Measuring Bush Bore Diameter Of Cylinder Head
      G04974763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 a 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.

    3. Heat the cylinder head to 80 to 100°C (176 to 212°F).
    4. Place the cylinder head on wooden blocks.
    5. Using SST, tap in a new valve guide bush to the specified protrusion height.

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

      Protrusion height: 9.30 to 9.70 mm (0.3661 to 0.3819 in.) 

      Fig 14: Tapping Valve Guide Bush
      G04996865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a sharp 5.5 mm reamer, ream the valve guide bushing to obtain the standard specified clearance.

      Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.) 

      Fig 15: Reaming Valve Guide Bushing
      G04974765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL CONNECTING ROD SMALL END BUSH 
    1. Align the oil holes of a new bush and the connecting rod.
      Fig 16: Aligning Oil Holes Of Bush And Connecting Rod
      G04996867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press in the bush.

      SST 09222-30010 

      Fig 17: Pressing Bush
      G04996868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a pin hole grinder, hone the bush to obtain the standard clearance between the bush and piston pin.
      Fig 18: Honing Bush
      G04996869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check that the piston pin fits at normal room temperature.
      1. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
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