CYLINDER HEAD REASSEMBLY

CAUTION / NOTICE / HINT

Tip:

Perform "Inspection After Repair" after replacing the cylinder head sub-assembly.

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PROCEDURE

  1. INSTALL SPARK PLUG TUBE

    Note:

    When using a new cylinder head sub-assembly, the spark plug tubes must be replaced.

    1. A194988C02

      *a

      1.0 to 3.0 mm (0.0394 to 0.118 in.)

      *b

      1.0 to 13.0 mm (0.0394 to 0.512 in.)

      Apply adhesive to the area of a new spark plug tube shown in the illustration.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Standard application width

      1.0 to 3.0 mm (0.0394 to 0.118 in.)

      Note:

      • Install the spark plug tube within 3 minutes of applying adhesive.

      • Be careful not to deform the spark plug tube.

      • Be careful not to expose the adhesive to engine oil for at least 1 hour after installing the spark plug tube.

    2. A205906C01

      *a

      Cylinder Head Casting Surface

      Using a wooden block and hammer, tap in the spark plug tube to the specified protrusion height.

      Standard protrusion height

      122 mm (4.80 in.)

      Note:

      To avoid tapping in the spark plug tube too far, measure the protrusion height while tapping it.

  2. INSTALL NO. 2 STRAIGHT SCREW PLUG

    Note:

    If water leaks from the No. 2 straight screw plug or the plug is corroded, replace it.

    1. A150950

      Using a 10 mm straight hexagon wrench, install 3 new gaskets and the 3 No. 2 straight screw plugs.

      44 N*m

      449 kgf*cm

      32 ft.*lbf

  3. INSTALL VALVE SPRING SEAT

    1. Install the valve spring seats to the cylinder head sub-assembly.

  4. INSTALL VALVE STEM OIL SEAL

    1. A146313C08

      *a

      Intake Side

      *b

      Exhaust Side

      *c

      Gray

      *d

      Black

      Apply a light coat of engine oil to new valve stem oil seals.

      Note:

      Pay close attention when installing the intake and exhaust valve stem oil seals. For example, installing the intake oil seal to the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.

      Tip:

      The intake valve stem oil seal is gray and the exhaust valve stem oil seal is black.

    2. A150956C02

      *a

      Correct

      *b

      Incorrect

      Using SST, push in the valve stem oil seals.

      09201-41020

      Note:

      Make sure to use SST, or the valve stem oil seals may be damaged or improperly seated.

  5. INSTALL INTAKE VALVE

    A314486C01

    *A

    Type A

    *B

    Type B

    *1

    No. 1 Valve Rocker Arm Sub-assembly

    *2

    Valve Spring Retainer

    *3

    Compression Spring

    *4

    Valve Lash Adjuster Assembly
    Tip:

    Type A and Type B can be distinguished by the shape of the compression spring.

    Type

    Compression Spring Shape

    A

    Straight

    B

    Tapered

    1. Type A:

      1. Place the cylinder head on wooden blocks.

      2. A146314C04

        *a

        30 mm (1.18 in.) or more

        Apply engine oil to the tip area of the intake valve, as shown in the illustration.

      3. Install the intake valve, inner compression spring and valve spring retainer to the cylinder head.

        Note:

        Install the same parts in the same combination to the original locations.

      4. A150946N05

        Using SST, compress the inner compression spring and install the valve spring retainer locks.

        09202-70020

        09202-00010

      5. A150974

        Using a plastic-faced hammer, lightly tap the intake valve stem tip to ensure a proper fit.

        Note:

        • Be careful not to damage the intake valve stem tip.

        • Be careful not to damage the valve spring retainer.

    2. Type B:

      1. Place the cylinder head on wooden blocks.

      2. A146314C06

        *a

        30 mm (1.18 in.) or more

        Apply engine oil to the tip area of the intake valve, as shown in the illustration.

      3. A314495C01

        *1

        Compression Spring

        *2

        Valve Spring Retainer

        *3

        Cylinder Head

        *4

        Upper Side

        Install the intake valve, inner compression spring and valve spring retainer to the cylinder head.

        Note:

        • Install the compression spring with its taperside facing upward (towards the valve spring retainer).

        • Install the same parts in the same combination to the original locations.

      4. A331963C01

        *a

        Wooden Block

        Using SST, compress the inner compression spring and install the valve spring retainer locks.

        09202-70020

        09202-00020

      5. A331965

        Using a plastic-faced hammer, lightly tap the intake valve stem tip to ensure a proper fit.

        Note:

        • Be careful not to damage the intake valve stem tip.

        • Be careful not to damage the valve spring retainer.

  6. INSTALL EXHAUST VALVE

    A314486C01

    *A

    Type A

    *B

    Type B

    *1

    No. 1 Valve Rocker Arm Sub-assembly

    *2

    Valve Spring Retainer

    *3

    Compression Spring

    *4

    Valve Lash Adjuster Assembly
    Tip:

    Type A and Type B can be distinguished by the shape of the compression spring.

    Type

    Compression Spring Shape

    A

    Straight

    B

    Tapered

    1. Type A:

      1. Place the cylinder head on wooden blocks.

      2. A146315C03

        *a

        30 mm (1.18 in.) or more

        Apply engine oil to the tip area of the exhaust valve, as shown in the illustration.

      3. Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head.

        Note:

        Install the same parts in the same combination to the original locations.

      4. A150947N09

        Using SST, compression the inner compression spring and install the valve spring retainer locks.

        09202-70020

        09202-00010

      5. A150973

        Using a plastic-faced hammer, lightly tap the exhaust valve stem tip to ensure a proper fit.

        Note:

        • Be careful not to damage the exhaust valve stem tip.

        • Be careful not to damage the valve spring retainer.

    2. Type B:

      1. Place the cylinder head on wooden blocks.

      2. A146315C04

        *a

        30 mm (1.18 in.) or more

        Apply engine oil to the tip area of the exhaust valve, as shown in the illustration.

      3. A314495C01

        *1

        Compression Spring

        *2

        Valve Spring Retainer

        *3

        Cylinder Head

        *4

        Upper Side

        Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head.

        Note:

        • Install the compression spring with its taperside facing upward (towards the valve spring retainer).

        • Install the same parts in the same combination to the original locations.

      4. A331964C01

        *a

        Wooden Block

        Using SST, compression the inner compression spring and install the valve spring retainer locks.

        09202-70020

        09202-00020

      5. A331966

        Using a plastic-faced hammer, lightly tap the exhaust valve stem tip to ensure a proper fit.

        Note:

        • Be careful not to damage the exhaust valve stem tip.

        • Be careful not to damage the valve spring retainer.

  7. INSTALL VALVE STEM CAP

    1. Apply a light coat of engine oil to the valve stem caps.

    2. Install the 16 valve stem caps.

      Tip:

      Do not drop the valve stem caps into the cylinder head sub-assembly.