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Engine Unit: Replacement

WARNING: This page is about a different car, the 2007 Toyota Tacoma. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE TIMING CHAIN COVER OIL SEAL 
    1. Using a screwdriver with its tip taped, pry out the oil seal.

      HINT:

      Tape the screwdriver tip before use.

      Fig 1: Prying Out Oil Seal Using Screwdriver
      G04408961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL TIMING CHAIN COVER OIL SEAL 
    1. Place the timing chain cover on wooden blocks.
    2. Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.

      SST 09223-50010 

      NOTE:
      • Keep the lip free from foreign matter.
      • Do not tap the oil seal at an angle.
        Fig 2: Tapping In New Oil Seal Using SST
        G04408962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE ENGINE REAR OIL SEAL 
    1. Place the oil seal retainer on wooden blocks.
    2. Using a screwdriver with its tip taped and a hammer, tap out the oil seal.

      HINT:

      Tape the screwdriver tip before use.

      Fig 3: Tapping Out Oil Seal Using Screwdriver
      G04408963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. 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, 09950-70010 (09951-07150) 

      NOTE:
      • Keep the lip free from foreign matter.
      • Do not tap the oil seal at an angle.
        Fig 4: Tapping In New Oil Seal Using SST
        G04408964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE INTAKE VALVE GUIDE BUSH 
    1. Heat the cylinder head to 80 to 100°C (176 to 212°F).
      Fig 5: Heating Cylinder Head
      G04408965Courtesy 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 09201-01055, 09950-70010 (09951-07100) 

      Fig 6: Tapping Out Guide Bush Using SST & Hammer
      G04408966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 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) 

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

      Bush bore diameter Bush size
      10.285 to 10.306 mm (0.4049 to 0.4057 in.) Use STD
      10.335 to 10.356 mm (0.4069 to 0.4077 in.) Use O/S 0.05
      Fig 7: Measuring Bush Bore Diameter Of Cylinder Head Using Caliper Gauge
      G04408967Courtesy 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).
      Fig 8: Heating Cylinder Head
      G04408968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Place the cylinder head on wooden blocks.
    5. Using SST, tap in a new valve guide bush to the specified protrusion height.

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

      Protrusion height (A): 9.8 to 10.2 mm (0.3858 to 0.4016 in.) 

      Fig 9: Tapping In New Valve Guide Bush Using SST
      G04408969Courtesy 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 10: Reaming Valve Guide Bush
      G04408970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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 09201-01055, 09950-70010 (09951-07100) 

      Fig 11: Tapping Out Guide Bush Using SST & Hammer
      G04408971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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) 

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

      Bush bore diameter Bush size
      10.285 to 10.306 mm (0.4049 to 0.4057 in.) Use STD
      10.335 to 10.356 mm (0.4069 to 0.4077 in.) Use O/S 0.05
      Fig 12: Measuring Bush Bore Diameter Of Cylinder Head Using Caliper Gauge
      G04408972Courtesy 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).
      Fig 13: Heating Cylinder Head
      G04408973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Place the cylinder head on wooden blocks.
    5. Using SST, tap in a new valve guide bush to the specified protrusion height.

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

      Protrusion height (A): 7.6 to 8.0 mm (0.2992 to 0.3150 in.) 

      Fig 14: Tapping In New Valve Guide Bush Using SST
      G04408974Courtesy 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
      G04408975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE CONNECTING ROD SMALL END BUSH 
    1. Using SST and a press, press out the bush.

      SST 09222-30010 

      Fig 16: Pressing Rod Small End Bushing Using SST And Press
      G04056220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL CONNECTING ROD SMALL END BUSH 
    1. Align the oil holes of a new bush and the connecting rod.
      Fig 17: Aligning Oil Holes Of New Bush & Connecting Rod
      G04408977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press in the bush.

      SST 09222-30010 

      Fig 18: Pressing Rod Small End Bushing Using SST And Press
      G04056220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a pin hole grinder, hone the bush to obtain the standard specified clearance (see step 26.) between the bush and piston pin.
      Fig 19: Grinding Pin Hole
      G04408979Courtesy 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.
        Fig 20: Checking Piston Pin
        G04408980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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