Engine Mechanical Cylinder Head: Overview Toyota Prius I рестайлинг

Locating Component Index (1 Of 3). Scheme 64

Locating Component Index (2 Of 3). Scheme 65

Locating Component Index (3 Of 3). Scheme 66

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1. Disconnect BATTERY NEGATIVE (-) TERMINAL AND HV BATTERY SERVICE PLUG.
2. Remove OUTER FRONT COWL TOP PANEL ASSEMBLY.
3. Drain HV Transaxle Coolant. See «DRAINING & REFILLING»(ref-142491-S24147200132002080600000).
4. Drain Engine Coolant.
5. Remove CONVERTER AND INVERTER ASSEMBLY.
6. Remove Air Cleaner Assembly. Disconnect the MAF meter connector. Disconnect the EVAP hose from the air cleaner case. Loosen the 2 hose clamps. Remove the 3 bolts and air cleaner assembly. (Scheme 67): Removing Air Cleaner Assembly
7. Remove IGNITION COILS.
8. Remove SPARK PLUGS.
9. Remove PCV Hoses.
10. Remove THROTTLE BODY. (Scheme 68): Removing Ignition Coils
11. Disconnect Engine Wire From Cylinder Head (Scheme 69): Disconnecting Engine Wire From Cylinder Head Disconnect the ECT sensor connector. Disconnect the camshaft position sensor connector. Disconnect the oil control valve connector. Disconnect the 4 injector connectors. Remove the 3 bolts and disconnect the engine wire protector from the cylinder head cover.
12. Remove Intake Manifold Remove the 3 bolts, 2 nuts intake manifold and gasket. (Scheme 70): Removing 3 Bolts, 2 Nuts Intake Manifold And Gasket
13. Disconnect Front Exhaust Pipe From Exhaust Manifold Remove the 2 bolts and 2 springs holding the front exhaust pipe to the exhaust manifold. (Scheme 71): Removing 2 Bolts And 2 Springs Holding Front Exhaust Pipe To Exhaust Manifold Remove the gasket.
14. Remove Exhaust Manifold Stay Remove the 3 bolts and exhaust manifold stay. (Scheme 72): Removing 3 Bolts And Exhaust Manifold Stay
15. Remove Exhaust Manifold Remove the 4 bolts and upper heat insulator. Remove the 3 bolts 2 nuts, exhaust manifold and gasket.
16. Remove Camshaft Position Sensor.
17. Remove ECT Sensor.
18. Remove Oil Control Valve.
19. Remove PCV Valve.
20. Remove Oil Filler Cap.
21. Remove head cover. «COMPONENTS»(/toyota/prius/i-2000-2003/remont/mechanical/#timing-chain). (Scheme 73): Removing Exhaust Manifold
22. Remove INJECTOR.
23. Remove timing chain cover. «COMPONENTS»(/toyota/prius/i-2000-2003/remont/mechanical/#timing-chain).
24. Remove Camshaft Timing Sprocket And Valve Timing Control Assembly Hold the hexagonal head portion of the camshaft with a wrench, and remove the 2 bolts and timing sprocket and valve timing controller assembly.
25. Remove Camshafts Uniformly loosen and remove the 19 bearing cap bolts, in several passes, in the sequence shown, and remove the 9 bearing caps, intake and exhaust camshafts.
26. Remove Cylinder Head Disconnect the upper radiator hose from the water hose union Disconnect the heater water hose from the water hose union NOTE: Head warpage or cracking could result from removing bolts in an incorrect order. Using a 8 mm bi-hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 cylinder head bolts and plate washers. Remove the bolt holding the water bypass pipe to the cylinder head. (Scheme 75): Removing 10 Cylinder Head Bolts NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver. (Scheme 76): Prying Between Cylinder Head And Cylinder Block With A Screwdriver Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on wooden blocks on a bench.

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1. Remove Valve Lifters
2. Remove Valves Using SST, compress the valve spring and remove the 2 keepers. SST 09202-70020 (09202-00010) Remove the spring retainer. Remove the valve spring. Remove the valve. (Scheme 77): Removing Valve Using needle-nose pliers, remove the oil seal. (Scheme 78): Removing Oil Seal NOTE: Arrange the valves, valve springs, spring seats and spring retainers in the correct order. (Scheme 79): Removing Spring Seat By Blowing Air Using compressed air and a magnetic finger, remove the spring seat by blowing air.

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1. Clean Top Surfaces Of Pistons And Cylinder Block Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston surface. (Scheme 80): Removing All Carbon From Piston Surface Using a gasket scraper, remove all the gasket material from the cylinder block surface. CAUTION: Protect your eyes when using high pressure compressed air. Using compressed air, blow carbon and oil from the bolt holes. (Scheme 81): Removing All Gasket Material From Cylinder Block Surface
2. Remove Gasket Material Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTE: Be careful not to scratch the cylinder block contact surface. (Scheme 82): Removing All Gasket Material From Cylinder Block Contact Surface
3. Clean Combustion Chambers Using a wire brush, remove all the carbon from the combustion chambers. NOTE: Be careful not to scratch the cylinder block contact surface. (Scheme 83): Removing All Carbon From Combustion Chambers
4. Clean Cylinder Head Using a soft brush and solvent, thoroughly clean the cylinder head. (Scheme 84): Cleaning Cylinder Head
5. Clean Valve Guide Bushings Using a valve guide bushing brush and solvent, clean all the guide bushings. (Scheme 85): Cleaning Valve Guide Bushings
6. Inspect For Flatness Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder block and the manifolds for warpage. Maximum warpage: INSPECT FOR FLATNESS Component Side Specifications Cylinder Block Side 0.05 mm (0.0020 in.) Intake Manifold Side 0.10 mm (0.0394 in.) Exhaust Manifold Side 0.10 mm (0.0394 in.) If warpage is greater than maximum, replace the cylinder head. (Scheme 86): Measuring Surface Contacting Cylinder Block And Manifolds
7. Inspect For Cracks Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. (Scheme 87): Inspecting For Cracks
8. Clean Valves Using a gasket scraper, chip off any carbon from the valve head. (Scheme 88): Cleaning Valves Using a wire brush, thoroughly clean the valve.
9. Inspect Valve Stems And Guide Bushings Using a caliper gauge, measure the inside diameter of the guide bushing. (Scheme 89): Measuring Inside Diameter Of Guide Bushing Bushing inside diameter: 5.010 - 5.030 mm (0.19724 - 0.19803 in.) Using a micrometer, measure the diameter of the valve stem. (Scheme 90): Measuring Diameter Of Valve Stem Valve stem diameter: Intake 4.970 - 4.985 mm (0.19567 - 0.19626 in.) Exhaust 4.965 - 4.980 mm (0.19547 - 0.19606 in.) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake 0.025 - 0.060 mm (0.00098 - 0.00236 in.) Exhaust 0.030 - 0.065 mm (0.00118 - 0.00256 in.) Maximum oil clearance: Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the valve and guide bushing.
10. Inspect Valves Check the valve is ground to the correct valve face angle. (Scheme 91): Checking Valve Is Ground To Correct Valve Face Angle Valve face angle: 44.5° Check that the surface of the valve for wear. If the valve face is worn, replace the valve. Check the valve head margin thickness. (Scheme 92): Checking Valve Head Margin Thickness Standard margin thickness: 1.00 - 1.15 mm (0.0393 - 0.0453 in.) Minimum margin thickness: 0.7 mm (0.028 in.) If the margin thickness is less than minimum, replace the valve. Check the valve overall length. (Scheme 93): Checking Valve Overall Length Standard overall length: Intake 89.25 mm (3.5138 in.) Exhaust 87.90 mm (3.4606 in.) Minimum overall length: Intake 88.95 mm (3.5020 in.) Exhaust 87.60 mm (3.4488 in.) If the overall length is less than minimum, replace the valve. Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve.
11. Inspect And Clean Valve Seats Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats. (Scheme 94): Resurfacing valve seats Check the valve seating position. Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve. Check the valve face and seat for the following: If blue appears 360° around the face, the valve is concentric. If not, replace the valve. If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat. (Scheme 95): Checking Valve Seating Position Check that the seat contact is in the middle of the valve face with the following width: 1.0 - 1.4 mm (0.039 - 0.055 in.) If not, correct the valve seats as follows: If the seating is too high on the valve face, use 20° and 45° cutters to correct the seat. (Scheme 96): Correcting Value Face High Seating If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. (Scheme 97): Correcting Seat Size Hand-lap the valve and valve seat with an abrasive compound. After hand-lapping, clean the valve and valve seat. (Scheme 98): Cleaning Valve And Valve Seat
12. Inspect Valve Springs Using a steel square, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) Maximum angle (reference): 2° If the deviation is greater than maximum, replace the valve spring. (Scheme 99): Measuring Deviation Of Valve Spring Using vernier calipers, measure the free length of the valve spring. Free length: 59.77 mm (2.353 in.) If the free length is not as specified, replace the valve spring. (Scheme 100): Measuring Free Length Of Valve Spring Using a spring tester, measure the tension of the valve spring at the specified installed length. (Scheme 101): Measuring Tension Of Valve Spring At Specified Installed Length Installed tension: 140 - 154 N (14.3 - 15.7 kgf, 31.5 - 34.6 lbf) at 32.5 mm (1.280 in.) Maximum working tension: 180 - 198 N (18.4 - 20.2 kgf, 40.4 - 44.8 lbf) at 25.1 mm (0.988 in.) If the installed tension is not as specified, replace the valve spring
13. Inspect Camshaft For Runout (Scheme 102): Measuring Circle Runout At Center Journal Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than maximum, replace the camshaft.
14. Inspect Cam Lobes Using a micrometer, measure the cam lobe height. (Scheme 103): Measuring Cam Lobe Height Standard cam lobe height: Intake 42.310 - 42.410 mm (1.62637 - 1.66968 in.) Exhaust 44.046 - 44.146 mm (1.73409 - 1.73803 in.) Minimum cam lobe height: Intake 42.16 mm (1.6598 in.) Exhaust 43.90 mm (1.7283 in.) If the cam lobe height is less than minimum, replace the camshaft.
15. Inspect Camshaft Journals Using a micrometer, measure the journal diameter. (Scheme 104): Measuring Journal Diameter No.1 journal diameter: 34.449 - 34.465 mm (1.35626 - 1.35689 in.) Others journal diameter: 22.949 - 22.965 mm (0.90350 - 0.90413 in.) If the journal diameter is not as specified, check the oil clearance.
16. Inspect Camshaft Journal Clearance (Scheme 105): Laying Strip Of Plastigage Across Each Of Camshaft Journal Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. NOTE: Do not turn the camshaft. Lay a strip of Plastigage across each of the camshaft journal. Install the bearing caps (See page EIVMt5). Torque: No.1 23 N.m (235 kgf.cm, 17 ft.lbf) No.2 12.7 N.m (130 kgf.cm, 10 ft.lbf) Remove the bearing caps. (Scheme 106): Removing Bearing Caps Measure the plastigage at its widest point. (Scheme 107): Measuring Plastigage At Widest Point Standard oil clearance: 0.040 - 0.095 mm (0.00157 - 0.00374 in.) Maximum oil clearance: 0.115 mm (0.00453 in.) If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. Completely remove the Plastigage. Remove the camshafts.
17. Inspect Camshaft Thrust Clearance (Scheme 108): Measuring Thrust Clearance While Moving Camshaft Back And Forth Install the camshafts (See «INSTALLATION»(ref-182297-S28054565392005080800000) ). Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.040 - 0.095 mm (0.0016 - 0.0037 in.) Maximum thrust clearance: 0.11 mm (0.0043 in.) If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. Remove the camshafts.
18. Inspect Valve Lifters And Lifter Bores Using a caliper gauge, measure the lifter bore diameter of the cylinder head. (Scheme 109): Measuring Lifter Bore Diameter Of Cylinder Head Lifter bore diameter: 31.009 - 31.025 mm (1.22082 - 1.22145 in.) Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 - 30.976 mm (1.21913 - 1.21953 in.) Subtract the lifter diameter measurement from the lifter bore diameter measurement. (Scheme 110): Measuring Lifter Diameter Standard oil clearance: 0.031 - 0.059 mm (0.00122 - 0.00232 in.) Maximum oil clearance: 0.1 mm (0.004 in.) If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head.
19. Inspect Intake Manifold Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. (Scheme 111): Measuring Surface Contacting Cylinder Head For Warpage (Intake Manifold) Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the manifold.
20. Inspect Exhaust Manifold Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. (Scheme 112): Measuring Surface Contacting Cylinder Head For Warpage (Exhaust Manifold) Maximum warpage: 0.70 mm (0.0276 in.) If warpage is greater than maximum, replace the manifold.

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1. Gradually heat the cylinder head to 80 - 100°C (176 -212°F). (Scheme 113): Heating Cylinder Head To 80 - 100°C (176 -212°F)
2. Using SST and a hammer, tap out the guide bushing. SST 09201-01055, 09950-70010 (09951-07100) (Scheme 114): Taping Out Guide Bushing Using SST
3. Using a caliper gauge, measure the bushing bore diameter of the cylinder head. (Scheme 115): Measuring Bushing Bore Diameter Of Cylinder Head
4. Select the new guide bushing (STD or O/S 0.05). (Scheme 116): Bushing Bore Diameter Chart If the bushing bore diameter of the cylinder head is greater than 9.706 mm (0.38213 in.), machine the bushing bore to the following dimension: 9.735 - 9.756 mm (0.38327 - 0.38493 in.) If the bushing bore diameter of the cylinder head is greater than 9.756 mm (0.38493 in.), replace the cylinder head.
5. Gradually heat the cylinder head to 80 - 100°C (176 -212°F).
6. Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. see scheme 54: Taping In Guide Bushing To Specified Protrusion Height SST 09201-01055, 09950-70010 (09951-07100) Protrusion height: 9.0 - 9.4 mm (0.354 - 0.370 in.)
7. Using a sharp 5 mm reamer, ream the guide bushing to obtain the standard specified clearance (See «INSPECTION»(ref-182297-S28437080992005080800000) ) between the guide bushing and valve stem.

Measuring specified clearance Between Guide Bushing And Valve Stem. Scheme 117

See also:
• COMPONENTS