CYLINDER HEAD REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

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

PROCEDURE


  1. INSTALL SPARK PLUG TUBE

    Tech Tips

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


    1. A01W59VE04
      Text in Illustration
      *a Adhesive
      *b Application Width
      *c Distance

      Apply adhesive to 4 new spark plug tubes as 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.)
      Distance
      1.0 to 7.0 mm (0.0394 to 0.276 in.)

      Note


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

      • Be careful not to deform the spark plug tube.

      • Do not expose the spark plug tube to engine oil for at least 1 hour after installing it.

    2. A01W5EJE02
      Text in Illustration
      *a Protrusion Height

      Using a wooden block and hammer, tap in the 4 spark plug tubes to the specified protrusion height.

      Standard Protrusion Height
      112 mm (4.41 in.)

      Note

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

  2. INSTALL CYLINDER HEAD STUD BOLT


    1. Using an E8 and E10 "TORX" socket wrench, install the 9 cylinder head stud bolts.

      A01VZMLE02
      Text in Illustration
      *a Intake Manifold Side *b Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst) Side
      *c Rear Side *d 26 mm (1.02 in.)
      *e 16.7 mm (0.657 in.) *f 51.7 mm (2.04 in.)
      *g 14 mm (0.551 in.) *h 13 mm (0.512 in.)
      *i 29 mm (1.14 in.) - -
      Torque:
      Stud Bolt (A), (C)
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }
      Stud Bolt (B)
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  3. INSTALL NO. 1 STRAIGHT SCREW PLUG


    1. A01W335

      Using a 10 mm hexagon wrench, install 3 new gaskets and the 3 No. 1 straight screw plugs.

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

  4. INSTALL NO. 2 STRAIGHT SCREW PLUG


    1. A01W4T9

      Using a 14 mm hexagon wrench, install a new gasket and the No. 2 straight screw plug.

      Torque:
      78 N*m  { 795 kgf*cm, 58 ft.*lbf }

  5. INSTALL VALVE SPRING SEAT


    1. Install the 16 valve spring seats to the cylinder head sub-assembly.

  6. INSTALL VALVE STEM OIL SEAL


    1. A01VZTUE01
      Text in Illustration
      *a Intake Valve Stem Oil Seal
      *b Exhaust Valve Stem Oil Seal
      *c Brown
      *d Gray
      *e "NOK" Mark

      Apply a light coat of engine oil to 16 new valve stem oil seals.

      Note

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

      Tech Tips

      The intake valve stem oil seals are brown and the exhaust valve stem oil seals are gray.

    2. A01W46GE01
      Text in Illustration
      *a Correct
      *b Incorrect

      Using SST, push in the 16 valve stem oil seals.

      SST
      09201-41020

      Note

      Failure to use SST will cause the valve stem oil seal to be damaged or improperly seated.

  7. INSTALL EXHAUST VALVE


    1. A01W3F4E06
      Text in Illustration
      *a 30 mm (1.18 in.) or more

      Sufficiently apply engine oil to the tip area of the exhaust valve shown in the illustration.

    2. Install the 8 exhaust valves, 8 compression springs and 8 valve spring retainers to the cylinder head sub-assembly.

      Note

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

    3. A01W2B2E02

      Using SST, compress the compression spring and install the 16 valve spring retainer locks.

      SST
      09202-70020   ( 09202-01010, 09202-01020 )
      09202-00020
    4. A01W5FA

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

      Note

      Be careful not to damage the valve spring retainer.

  8. INSTALL INTAKE VALVE


    1. A01W3F4E06
      Text in Illustration
      *a 30 mm (1.18 in.) or more

      Sufficiently apply engine oil to the tip area of the intake valve shown in the illustration.

    2. Install the 8 intake valves, 8 compression springs and 8 valve spring retainers to the cylinder head sub-assembly.

      Note

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

    3. A01W4S9E02

      Using SST, compress the compression spring and install the 16 valve spring retainer locks.

      SST
      09202-70020   ( 09202-01010, 09202-01020 )
      09202-00020
    4. A01W2XN

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

      Note

      Be careful not to damage the valve spring retainer.