Toyota Yaris: Cylinder Head / Replacement

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (engine Mechanical) / Cylinder Head / Replacement

REPLACEMENT

PROCEDURE

1. REPLACE INTAKE VALVE GUIDE BUSH

(a) Heat the cylinder head sub-assembly to between 80 and 100°C (176 to 212°F).

(b) Place the cylinder head sub-assembly on wooden blocks.

CAUTION:

Be sure to wear protective gloves.

(c) Using SST and a hammer, tap out the intake valve guide bush.

SST: 09201-01055

SST: 09950-70010

09951-07100

(d) Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head sub-assembly.

Standard Intake Valve Guide Bush Bore Diameter:

10.285 to 10.306 mm (0.405 to 0.406 in.)

New Guide Bush Selection Chart:

Bush Size

Specified Condition

STD

10.333 to 10.344 mm (0.40681 to 0.40724 in.)

O/S 0.05

10.383 to 10.394 mm (0.40877 to 0.40921 in.)

Standard Bush Length:

41.3 to 41.7 mm (1.63 to 1.64 in.)

HINT:

  • If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.406 in.), machine the intake valve guide bush bore of the cylinder head sub-assembly to a dimension of 10.335 to 10.356 mm (0.407 to 0.408 in.) to install an O/S 0.05 intake valve guide bush.
  • If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.408 in.), replace the cylinder head sub-assembly.

(e) Heat the cylinder head sub-assembly to between 80 and 100°C (176 to 212°F).

(f) Using SST and a hammer, tap in the selected intake valve guide bush.

SST: 09201-10000

09201-01050

SST: 09950-70010

09951-07100

Standard Protrusion Height:

13.35 to 13.60 mm (0.526 to 0.535 in.)

*a

Protrusion Height

(g) Using a sharp 5.5 mm reamer, ream the intake valve guide bush to obtain the standard oil clearance.

Standard Oil Clearance:

0.025 to 0.060 mm (0.000984 to 0.00236 in.)

2. REPLACE EXHAUST VALVE GUIDE BUSH

(a) Heat the cylinder head sub-assembly to between 80 and 100°C (176 to 212°F).

(b) Place the cylinder head sub-assembly on wooden blocks.

CAUTION:

Be sure to wear protective gloves.

(c) Using SST and a hammer, tap out the exhaust valve guide bush.

SST: 09201-01055

SST: 09950-70010

09951-07100

(d) Using a caliper gauge, measure the exhaust valve guide bush bore diameter of the cylinder head sub-assembly.

Standard Exhaust Valve Guide Bush Bore Diameter:

10.285 to 10.306 mm (0.405 to 0.406 in.)

New Guide Bush Selection Chart:

Bush Size

Specified Condition

STD

10.333 to 10.344 mm (0.40681 to 0.40724 in.)

O/S 0.05

10.383 to 10.394 mm (0.40877 to 0.40921 in.)

Standard Bush Length:

43.3 to 43.7 mm (1.70 to 1.72 in.)

HINT:

  • If the exhaust valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.306 mm (0.406 in.), machine the exhaust valve guide bush bore of the cylinder head sub-assembly to a dimension of 10.335 to 10.356 mm (0.407 to 0.408 in.) to install an O/S 0.05 exhaust valve guide bush.
  • If the exhaust valve guide bush bore diameter of the cylinder head sub-assembly is more than 10.356 mm (0.408 in.), replace the cylinder head sub-assembly.

(e) Heat the cylinder head sub-assembly to between 80 and 100°C (176 to 212°F).

(f) Using SST and a hammer, tap in the selected exhaust valve guide bush.

SST: 09201-10000

09201-01050

SST: 09950-70010

09951-07100

Standard Protrusion Height:

13.75 to 14.00 mm (0.541 to 0.551 in.)

*a

Protrusion Height

(g) Using a sharp 5.5 mm reamer, ream the exhaust valve guide bush to obtain the standard oil clearance.

Standard Oil Clearance:

0.030 to 0.065 mm (0.00118 to 0.00256 in.)

3. REPLACE RING PIN

NOTICE:

It is not necessary to remove the ring pins unless they are being replaced.

(a) Remove the 8 ring pins.

(b) Using a plastic hammer, tap in 8 new ring pins to the cylinder head sub-assembly.

Standard Protrusion Height:

RING PIN (A)

3.0 to 5.0 mm (0.118 to 0.197 in.)

RING PIN (B)

4.0 to 6.0 mm (0.157 to 0.236 in.)

*a

Protrusion Height

    Inspection

    INSPECTION PROCEDURE 1. INSPECT CYLINDER HEAD SUB-ASSEMBLY (a) Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head sub-assembly contacts the cylinder block sub-assembly, intake manifold and exhaust manifold...

    Reassembly

    REASSEMBLY PROCEDURE 1. INSTALL SPARK PLUG TUBE HINT: When using a new cylinder head sub-assembly, the spark plug tubes must be replaced. (a) Apply adhesive to a new spark plug tube as shown in the illustration...

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    Categories

    Break-In Period

    No special break-in is necessary, but a few precautions in the first 600 miles (1,000 km) may add to the performance, economy, and life of the vehicle.

    Do not race the engine. Do not maintain one constant speed, either slow or fast, for a long period of time. Do not drive constantly at full-throttle or high engine rpm for extended periods of time. Avoid unnecessary hard stops. Avoid full-throttle starts.

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