Cylinder Head: Replacement

WARNING: This page is about a different car, the 2008 Lexus LS 600hL. However, it is still accessible from the selected car via links, so may be relevant.

HINT.

When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side

REPLACE INTAKE VALVE GUIDE BUSH

Heat the cylinder head to approximately 80 to 100°C (176 to 212°F).
Place the cylinder head on wooden blocks.
Using SST and a hammer, tap out the valve guide bush.
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)

Fig 1: Removing Intake Valve Guide Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a caliper gauge, measure the bush bore diameter of the cylinder head side.
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 to 10.306 mm (0.405 to 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.

Fig 2: Measuring Bush Bore Diameter Of Cylinder Head Side
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Select a new guide bush (STD or O/S 0.05), and measure its diameter.

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

BUSH BORE DIAMETER

BUSH BORE DIAMETER SPECIFICATION

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 (1.63 to 1.64 in.)

Heat the cylinder head to approximately 80 to 100°C (176 to 212°F).
Using SST and a hammer, tap the guide bush to the specified protrusion height.
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)

Standard protrusion height:

14.3 to 14.7 mm (0.563 to 0.579 in.)

Fig 3: Tapping Guide Bush Using SST And Hammer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem

REPLACE EXHAUST VALVE GUIDE BUSH

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

Fig 4: Reaming Intake Valve Guide Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST and a hammer, tap out the valve guide bush.
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)

Fig 5: Removing Exhaust Valve Guide Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 to 10 306 mm (0.405 to 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

Fig 6: Measuring Bush Bore Diameter Of Cylinder Head
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Select a new guide bush (STD or O/S 0 05), and measure its diameter

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

BUSH BORE DIAMETER

BUSH BORE DIAMETER SPECIFICATION

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:

46.8 to 47.2 mm (1.84 to 1.86 in.)

Heat the cylinder head to approximately 80 to 100°C (176 to 212°F)
Using SST and a hammer, tap in the guide bush to the specified protrusion height.
SST 09201-10000 (09201-01050), 09950-70010 (09951-07100)

Standard protrusion height:

14.3 to 14.7 mm (0.563 to 0.579 in.)

Fig 7: Tapping In Exhaust Valve Guide Bush Using SST And Hammer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem.

Fig 8: Reaming Exhaust Valve Guide Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REPLACE SPARK PLUG TUBE
HINT:

When using a new cylinder head, the spark plug tubes must be replaced.
1. Remove the spark plug tube.
2. Apply adhesive to the end of a new spark plug tube.
  Adhesive:
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
  
  Standard seal diameter:
  
  15 mm (0.591 in.)
  
  Fig 9: Applying Adhesive To End Of Spark Plug Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - 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.
3. Using a wooden block and hammer, tap in the spark plug tube to the specified protrusion height.
  Standard protrusion height:
  
  66.6 to 67.6 mm (2.62 to 2.66 in.)
  
  NOTE: To avoid tapping in the spark plug tube too far, measure the protrusion height while tapping it.

REPLACE RING PIN

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

Remove the ring pins.

Using a plastic-faced hammer, tap in new ring pins until they stop.

STANDARD PROTRUSION

RING PIN PROTRUSION SPECIFICATION

Item	Specified Condition
Ring pin A	5.5 to 6.5 mm (0.217 to 0.256 in.)
Ring pin B	3.5 to 6.5 mm (0.138 to 0.256 in.)

Fig 10: Tapping In Spark Plug Tube

Fig 11: Identifying Ring Pins Dimensions