RM3090E _51 Engine / Hybrid System _008396 2AR-FE ENGINE MECHANICAL _0046873 CYLINDER HEAD A

2AR-FE ENGINE MECHANICAL  CYLINDER HEAD  REPLACEMENT  


PROCEDURE

Hide 11122 1.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.
A194970
0.131,0.115 0.426,0.278 0.295,0.163 10 SST 0.496,0.205 0.668,0.205 0.668,0.205 0.957,0.628 false
SST

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

SST
09201-01055  
09950-70010  (09951-07100)


d.

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

Standard bush bore diameter:

10.285 to 10.306 mm (0.405 to 0.406 in.)


If the bush bore diameter of the cylinder head is between 10.285 and 10.306 mm (0.405 and 0.406 in.), proceed to the next step.

If the bush bore diameter of the cylinder head is 10.356 mm (0.408 in.) or more, replace the cylinder head sub-assembly.


e.

Select a new guide bush (STD or O/S 0.05) and measure its diameter.


f.

Machine the bush bore of the cylinder head to the diameter of the selected guide bush.

Bush Bore Diameter:
Bush Size Specified Condition
STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.)
O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.)


Standard bush length:

41.3 to 41.7 mm (1.626 to 1.642 in.)



g.

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


h.
A194972
1.01,0.813 0.385,0.427 0.385,0.427 1.24,1.323 false 2.448,0.542 2.604,0.688 0.156,0.146 10 *1 0.021,0.344 0.323,0.49 0.302,0.146 10 SST
*1
SST
*1 Protrusion Height


Using SST and a hammer, tap in the selected guide bush to the standard protrusion height.

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

Standard protrusion height:

14.8 to 15.2 mm (0.582 to 0.598 in.)



i.
A194973

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

Standard oil clearance:

0.025 to 0.060 mm (0.000984 to 0.00236 in.)



Hide 11126 2.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.
A246228
0.19,0.121 0.504,0.287 0.314,0.166 10 SST 0.557,0.208 0.685,0.208 0.685,0.208 1.23,0.603 false
SST

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

SST
09201-01055  
09950-70010  (09951-07100)


d.

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

Standard bush bore diameter:

10.285 to 10.306 mm (0.405 to 0.406 in.)


If the bush bore diameter of the cylinder head is between 10.285 and 10.306 mm (0.405 and 0.406 in.), proceed to the next step.

If the bush bore diameter of the cylinder head is 10.356 mm (0.408 in.) or more, replace the cylinder head sub-assembly.


e.

Select a new guide bush (STD or O/S 0.05) and measure its diameter.


f.

Machine the bush bore of the cylinder head to the diameter of the selected guide bush.

Bush Bore Diameter:
Bush Size Specified Condition
STD 10.333 to 10.344 mm (0.4068 in 0.4072 in.)
O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.)


Standard bush length:

46.8 to 47.2 mm (1.843 to 1.858 in.)



g.

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


h.
A285337
1.146,1.177 0.615,0.323 0.615,0.323 1.208,0.656 false 2.979,1.313 3.292,1.469 0.313,0.156 10 *1 0.354,0.156 0.813,0.354 0.458,0.198 10 SST
*1
SST
*1 Protrusion Height


Using SST and a hammer, tap in the selected guide bush to the standard protrusion height.

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

Standard protrusion height:

14.2 to 14.6 mm (0.559 to 0.575 in.)



i.
A246230

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

Standard oil clearance:

0.030 to 0.065 mm (0.00118 to 0.00256 in.)



Hide 3.REPLACE SPARK PLUG TUBE

HINT:

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


a.
A194988
2.469,1.729 2.344,1.729 2.344,1.729 2.188,1.167 false 1.802,0.26 2.042,0.427 0.24,0.167 10 *2 2.5,1.646 2.74,1.813 0.24,0.167 10 *1 1.542,1.885 1.771,2.063 0.229,0.177 10 *3
*2
*1
*3
*1 Adhesive
*2 Application Width
*3 Distance


Apply adhesive onto the shaded area of a new spark plug tube.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.


Standard application width:

2.0 mm (0.0787 in.)


Distance:

6.0 mm (0.236 in.)


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 coolant for at least 1 hour after installing it.




b.
A194971
2.396,3.01 2.635,3.188 0.24,0.177 10 *1
*1
*1 Protrusion Height


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

Standard protrusion height:

112 mm (4.41 in.)


NOTICE:

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



Hide 11115A 4.REPLACE RING PIN

NOTICE:

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


a.

Remove the ring pins.


b.
A194963
2.208,2.333 2.438,2.51 0.229,0.177 10 *1
*1
*1 Protrusion Height


Using a plastic-faced hammer, tap in new ring pins to the cylinder head.

Standard protrusion height:

6.5 to 7.5 mm (0.256 to 0.295 in.)