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Engine Unit: Replacement: Replacement

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  1. REMOVE SPARK PLUG TUBE GASKET 
    1. Pry up the 3 claws of the ventilation baffle plate.
      Fig 1: Identifying Claws Of Ventilation Baffle Plate
      GTY192514Courtesy 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
      GTY192515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE ENGINE REAR OIL SEAL 
    1. Place the oil seal retainer on wooden blocks.
      Fig 3: Tapping Out Oil Seal
      GTY139678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the engine rear oil seal retainer.

    2. Using a screwdriver and a hammer, tap out the oil seal.

      HINT: 

      Tape the screwdriver tip before use.

  3. REMOVE TIMING CHAIN COVER OIL SEAL 
    1. Using a screwdriver, pry out the timing chain case oil seal.
      Fig 4: Prying Out Oil Seal Using Screwdriver
      GTY135959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Tape the screwdriver tip before use.

  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.
      Fig 5: Tapping Oil Seal Using SST
      GTY169620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • 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 does not stick out of the timing chain case.
  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.
      Fig 6: Installing Engine Rear Oil Seal Using SST
      GTY145954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09223-15030 
      • SST: 09950-70010 
        • 09951-07100
      NOTE:
      • Keep the lip free from foreign matter.
      • Do not tap on the oil seal at an angle.
  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.
      Fig 7: Tapping In Spark Plug Tube Gaskets To Head Covers
      GTY191675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  7. REMOVE INTAKE VALVE GUIDE BUSH 
    1. Heat the cylinder head to 80 to 100°C (176 to 212°F).
      Fig 8: Tapping Out Guide Bush Using SST
      GTY188357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the cylinder head on wooden blocks.
    3. Using SST and a hammer, tap out the guide bush.
      • SST: 09201-10000 
        • 09201-01050
      • SST: 09950-70010 
        • 09951-07100
  8. REMOVE EXHAUST VALVE GUIDE BUSH 
    1. Heat the cylinder head to 80 to 100°C (176 to 212°F).
      Fig 9: Tapping Out Guide Bush Using SST
      GTY177404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the cylinder head on wooden blocks.
    3. Using SST and a hammer, tap out the guide bush.
      • SST: 09201-10000 
        • 09201-01050
      • SST: 09950-70010 
        • 09951-07100
  9. INSTALL INTAKE VALVE GUIDE BUSH 
    1. Using a caliper gauge, measure the bush bore diameter of the cylinder head.
      Fig 10: Measuring Bush Bore Diameter Of Cylinder Head Using Caliper Gauge
      GTY145628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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).
      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.)

      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.
      Fig 11: Tapping In Valve Guide Bush Using SST
      GTY192516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST, tap in a new valve guide bush to the specified protrusion height.
      • SST: 09201-10000 
        • 09201-01050
      • SST: 09950-70010 
        • 09951-07100

      Protrusion height

      9.30 to 9.70 mm (0.3661 to 0.3819 in.)

    6. Using a sharp 5.5 mm reamer, ream the valve guide bush to obtain the standard specified clearance.
      Fig 12: Reaming Valve Guide Bush
      GTY127717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard oil clearance

      0.025 to 0.060 mm (0.0010 to 0.0023 in.)

  10. INSTALL EXHAUST VALVE GUIDE BUSH 
    1. Using a caliper gauge, measure the bush bore diameter of the cylinder head.
      Fig 13: Checking Bush Bore Diameter Of Cylinder Head
      GTY136289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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).
      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.)

      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.
      Fig 14: Tapping Valve Guide Bush Using SST
      GTY192517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST, tap in a new valve guide bush to the specified protrusion height.
      • SST: 09201-10000 
        • 09201-01050
      • SST: 09950-70010 
        • 09951-07100

      Protrusion height

      9.30 to 9.70 mm (0.3661 to 0.3819 in.)

    6. Using a sharp 5.5 mm reamer, ream the valve guide bushing to obtain the standard specified clearance.
      Fig 15: Reaming Valve Guide Bushing
      GTY145207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard oil clearance

      0.030 to 0.065 mm (0.0012 to 0.0026 in.)

  11. INSTALL CONNECTING ROD SMALL END BUSH 
    1. Align the oil holes of a new bush and the connecting rod.
      Fig 16: Identifying Oil Holes Of Bush And Connecting Rod
      GTY144792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press in the bush.
      Fig 17: Pressing Rod Small End Bushing Using SST And Press
      GTY191122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09222-30010 
    3. Using a pin hole grinder, hone the bush to obtain the standard clearance between the bush and piston pin.
      Fig 18: Checking Clearance Between Bush And Piston Pin
      GTY191123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check that the piston pin fits at normal room temperature.
      Fig 19: Checking Piston Pin Fitting
      GTY174810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
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