CYLINDER HEAD REASSEMBLY

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL SPARK PLUG TUBE

   Tech Tips

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

   
   
   1. 

      *a	Adhesive
      *b	Application Width
      *c	Distance

      Apply adhesive to a new spark plug tube 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.

   2. 

      *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.

      • 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 it.

2. INSTALL STUD BOLT

   Note

   If a stud bolt is deformed or its threads are damaged, replace it.

   
   

   1. Using E8 and E10 "TORX" socket wrenches, install the stud bolts.

      

      *a	Intake Manifold Side	*b	Front Side
      *c	Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst) Side	*d	Rear Side
      *e	26 mm (1.02 in)	*f	16.7 mm (0.657 in)
      *g	51.7 mm (2.04 in)	*h	13 mm (0.512 in)
      *i	48 mm (1.89 in)	*j	24.5 mm (0.965 in)
      *k	14 mm (0.551 in)	*l	40 mm (1.57 in.)
      *m	29 mm (1.14 in)	-	-

      Torque:

      Bolt (A), (B), (D)

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

      Bolt (C)

      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

3. INSTALL NO. 1 STRAIGHT SCREW PLUG

   
   

   1. 

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

      Torque:

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

4. INSTALL VALVE SPRING SEAT

   
   

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

5. INSTALL VALVE STEM OIL SEAL

   
   
   1. 

      *a	Intake Side
      *b	Exhaust Side
      *c	Mark "NOK"
      *d	Gray
      *e	Black

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

      Note

      Make sure to install each valve stem oil seal to the correct side. Installing an intake valve stem oil seal to the exhaust side or installing an exhaust valve stem oil seal to the intake side can cause installation problems later.

      Tech Tips

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

   2. 

      *a	Correct
      *b	Incorrect

      Using SST, push in the 8 intake valve stem oil seals and 8 exhaust valve stem oil seals.

      SST

      09201-41020

      Note

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

6. INSTALL INTAKE VALVE

   
   

   1. 

      *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. 

      *a	Narrow
      *b	Wide

      Install the 8 intake valves, 8 inner 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. 

      Using SST, compress the 8 inner compression springs and install the 8 valve spring retainer locks.

      SST

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

      09202-00021

   4. 

      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.

7. INSTALL EXHAUST VALVE

   
   

   1. 

      *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. 

      *a	Narrow
      *b	Wide

      Install the 8 exhaust valves, 8 inner 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. 

      Using SST, compress the 8 inner compression springs and install the 8 valve spring retainer locks.

      SST

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

      09202-00021

   4. 

      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.