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, the spark plug tubes must be replaced.


    1. A01W59VE03
      *1 1.0 to 3.0 mm
      *2 1.0 to 3.0 mm (0.0394 to 0.118 in.)

      Apply adhesive onto the shaded area of a new spark plug tube.

      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 after applying adhesive.

      • Be careful not to deform the spark plug tube.

      • Be careful not to expose the seal to coolant for at least 1 hour after installing it.

    2. A01W0BVE01
      Text in Illustration
      *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
      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. A01W4UDE10
      *1 18 mm (0.709 in.)
      *2 33 mm (1.30 in.)
      *3 13 mm (0.512 in.)

      Using an E7 "TORX" socket wrench, install the 5 cylinder head stud bolts.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  3. INSTALL NO. 1 STRAIGHT SCREW PLUG


    1. A01W2MT

      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 valve spring seats to the cylinder head sub-assembly.

  6. INSTALL VALVE STEM OIL SEAL


    1. A01W290E08
      Text in Illustration
      *a Intake
      *b Exhaust
      *c Mark "NOK"
      *d Gray
      *e Black

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

      Note

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

      Tech Tips

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

    2. A01W0J5E03
      Text in Illustration
      *a CORRECT
      *b INCORRECT

      Using SST, push in the valve stem oil seals.

      SST
      09201-41020

      Note

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

  7. INSTALL INTAKE VALVE

    Tech Tips

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

    A01W1X7E01
    Text in Illustration
    *A

    Type A

    (Compression Spring Shape: Straight)

    		 *B

    Type B

    (Compression Spring Shape: Tapered)
    *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Spring Retainer
    *3 Compression Spring *4 Valve Lash Adjuster Assembly

    1. A01VZPAE03
      Text in Illustration
      *a 30 mm (1.18 in.) or more

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

    2. Type A


      1. 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.

      2. A01W3MFE08

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

        SST
        09202-70020   ( 09202-00010, 09202-01010, 09202-01020 )

    3. Type B:


      1. A01W1Y8E05
        Text in Illustration
        *a Narrow
        *b Wide

        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.

      2. A01W2YNE01

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

        SST
        09202-00021
        09202-70020   ( 09202-01010, 09202-01020 )
    4. A01W35D

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

      Note

      Be careful not to damage the retainer.

  8. INSTALL EXHAUST VALVE

    Tech Tips

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

    A01W1X7E01
    Text in Illustration
    *A

    Type A

    (Compression Spring Shape: Straight)

    		 *B

    Type B

    (Compression Spring Shape: Tapered)
    *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Spring Retainer
    *3 Compression Spring *4 Valve Lash Adjuster Assembly

    1. A01VZPAE03
      Text in Illustration
      *a 30 mm (1.18 in.) or more

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

    2. Type A:


      1. 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.

      2. A01W2KSE07

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

        SST
        09202-70020   ( 09202-00010, 09202-01010, 09202-01020 )

    3. Type B:


      1. A01W0ICE04
        Text in Illustration
        *a Narrow
        *b Wide

        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.

      2. A01W0MZE06

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

        SST
        09202-00021
        09202-70020   ( 09202-01010, 09202-01020 )
    4. A01W4R0

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

      Note

      Be careful not to damage the retainer.