Engine Unit, Replacement

ENGINE UNIT

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

COMPONENTS:

REPLACEMENT





1. REPLACE SPARK PLUG TUBE GASKET
a. Pry up the claws of the ventilation baffle plate.





b. Using a screwdriver with its tip taped and a hammer, tap out the 6 spark plug tube gaskets.





c. Using a 32 mm socket wrench, tap in 6 new spark plug tube gaskets to the head covers.

NOTICE:
^ Keep the lip free from foreign matter.
^ Do not tap on the oil seal at an angle.

d. Return the claw of the ventilation baffle plate to its original position.





2. REPLACE ENGINE REAR OIL SEAL
a. Place the oil seal retainer on wooden blocks.
b. Using a screwdriver and a hammer, tap out the oil seal.





c. Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.
SST 09223-15030

NOTICE:
^ Keep the lip free from foreign matter.
^ Do not tap on the oil seal at an angle.





3. REPLACE CONNECTING ROD SMALL END BUSH
a. Using SST and a press, push out the bush.
SST 09222-30010





b. Align the oil holes of the new bush and connecting rod.





c. Using SST and a press, push in the bush.
SST 09222-30010





d. Using a pin hole grinder, hone the bush to obtain the standard specified clearance between the bush and piston pin.





e. Coat the piston pin with engine oil. Push the piston pin into the connecting rod with your thumb to check that the piston pin fits at normal room temperature.
4. 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. Using SST and a hammer, tap out the valve guide bush.
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)





d. Using a caliper gauge, measure the bush bore diameter of the cylinder head.
Standard cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 inch)
e. Select a new guide bush (STD or O/S 0.05).
Standard bush bore diameter

Standard bush bore diameter:

HINT:
^ If the bush bore diameter of the cylinder head is greater than 10.344 mm (0.4072 inch), machine the bush bore diameter to between 10.383 to 10.394 mm (0.4088 to 0.4092 inch).
^ If the bush bore diameter of the cylinder head is greater than 10.344 mm (0.4072 inch), replace the cylinder head.

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





g. Using SST and a hammer, tap in a new guide bush to the specified protrusion height.
Standard protrusion height: 9.1 to 9.9 mm (0.3582 to 0.3900 inch)
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)





h. Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem.
5. 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. Using SST and a hammer, tap out the valve guide bush.
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)





d. Using a caliper gauge, measure the bush bore diameter of the cylinder head.
Standard cylinder bore diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 inch)
e. Select a new guide bush (STD or O/S 0.05).
Standard bush bore diameter

Standard bush bore diameter:

HINT:
^ If the bush bore diameter of the cylinder head is greater than 10.344 mm (0.4072 inch), machine the bush bore diameter to between 10.383 to 10.394 mm (0.4088 to 0.4092 inch).
^ If the bush bore diameter of the cylinder head is greater than 10.344 mm (0.4072 inch), replace the cylinder head.

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





g. Using SST and a hammer, tap in a new guide bush to the specified protrusion height.
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)
Standard protrusion height: 9.30 to 9.70 mm (0.3661 to 0.3819 inch)





h. Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem.
6. REPLACE CYLINDER BLOCK TIGHT PLUG

NOTICE: If water leaks from the tight plug or the plug corrodes, replace it.

a. Remove the tight plugs.





b. Apply adhesive around the tight plug.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
c. Using SST and a hammer, tap in 2 new tight plugs as shown in the illustration.
SST 09950-60010 (09951-00340), 09950-70010 (09951-07100)





7. REPLACE CYLINDER BLOCK STUD BOLT

NOTICE: If a stud bolt is deformed or the threads are damaged, replace it.

a. Remove the stud bolts.
b. Using an E8 "Torx" socket wrench, install the stud bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)





8. REPLACE CYLINDER BLOCK STRAIGHT PIN

NOTICE: It is not necessary to remove the straight pin unless it is being replaced.

a. Remove the straight pin.
b. Using a plastic-faced hammer, tap in new straight pins to the cylinder block.
Standard protrusion

Standard protrusion:

9. REPLACE CYLINDER HEAD RING PIN

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

a. Remove the ring pins.





b. Using a plastic-faced hammer, tap in a new ring pin until the pin stops.
10. REPLACE CYLINDER HEAD STUD BOLT

NOTICE: If a stud bolt is deformed or the threads are damaged, replace it.

a. Remove the stud bolts.
b. Using E6 and E8 "Torx" socket wrenches, install the stud bolts.
Torque:
10 Nm (102 kgf-cm, 7 ft. lbs.) for stud bolts A and B
4.0 Nm (41 kgf-cm, 35 inch lbs.) for stud bolt C





11. REPLACE CYLINDER HEAD SET STRAIGHT PIN

NOTICE: It is not necessary to remove the straight pin unless it is being replaced.

a. Using a plastic-faced hammer, tap in a new straight pin as shown in the illustration.
Standard protrusion height: 18.0 to 19.0 mm (0.71 to 0.75 inch)