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(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 in.)
(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)
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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 N*m (102 kgf*cm, 7 ft.*lbf)
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.
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(b) Using a plastic-faced hammer, tap in new straight
pins to the cylinder block.
Standard protrusion
Item Specified Condition
Pin A 23 mm (0.91 in.)
Pin B 6 mm (0.24 in.)
Pin C 11 mm (0.43 in.)
Pin D 9 mm (0.35 in.)
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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 N*m (102 kgf*cm, 7 ft.*lbf) for stud
bolts A and B
4.0 N*m (41 kgf*cm, 35 in.*lbf) for stud
bolt C
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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 in.)
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REASSEMBLY
1. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Using a 5 mm hexagon wrench, install the 3 oil
nozzles with the bolts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
2. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSEMBLY
(a) Apply adhesive around the drain cocks.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond
1324 or Equivalent
(b) Install the cylinder block water drain cocks.
(1) Temporarily install the drain cocks.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
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(2) Within one full rotation, tighten the drain cock to
the angle shown in the illustration.
Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf)
NOTICE:
Do not loosen the drain cock to adjust it. If
an adjustment is necessary, remove the
drain cock and reinstall it.
(c) Install the water drain cock plug to the water drain
cocks.
Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
3. INSTALL PISTON WITH PIN SUB-ASSEMBLY
(a) Using a screwdriver, install a new snap ring at one
end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not
aligned with the pin hole cutout portion of the piston.
(b) Gradually heat the piston to approximately 80
C
(176
F).
(c) Coat the piston pin with engine oil.
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(d) Align the front marks of the piston and connecting
rod, and push in the piston pin with your thumb.
HINT:
The piston and pin are a matched set.
(e) Check the fitting condition between the piston and
piston pin by trying to move the piston back and
forth on the piston pin.
(f) Using a screwdriver, install a new snap ring at the
other end of the piston pin hole.
HINT:
Be sure that the end gap of the snap ring is not
aligned with the pin hole cutout portion of the piston.
4. INSTALL PISTON RING SET
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2
compression rings so that the painted marks are
positioned as shown in the illustration.
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