CYLINDER HEAD REASSEMBLY

Tech Tips


  • Thoroughly clean all parts to be assembled.

  • Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.

  • Replace all gaskets and oil seals with new ones.


  1. INSTALL INTAKE VALVE GUIDE BUSH


    1. A01KGCV

      Using a caliper gauge, measure the bush bore diameter of the cylinder head.

    2. Select a new guide bush (STD or O/S 0.05).

      Bush bore diameter Bush size
      13.004 - 13.025 mm (0.5120 - 0.5128 in.) Use STD
      13.054 - 13.075 mm (0.5139 - 0.5148 in.) Use O/S 0.05

      If the bush bore diameter of the cylinder head is greater than 13.025 mm (0.5128 in.), machine the bush bore to this dimension of 13.054 - 13.075 mm (0.5139 - 0.5148 in.).

      If the bush bore diameter of the cylinder head is greater than 13.075 mm (0.5139 in.), replace the cylinder head.

    3. A01KIDAE01

      Using SST and a hammer, tap in a new guide bush to the specified protrusion height.

      SST
      09201-10000   ( 09201-01080 )
      09950-70010   ( 09951-07100 )
      Protrusion height
      10.8 - 11.2 mm (0.425 - 0.441 in.)
    4. A01KETYE01
      Text in Illustration
      *1 8.0 mm Reamer

      Using a sharp 8.0mm reamer, ream the guide bush to obtain the standard specified clearance (See step Click here) between the guide bush and valve stem.

  2. INSTALL EXHAUST VALVE GUIDE BUSH


    1. A01KEQD

      Using a caliper gauge, measure the bush bore diameter of the cylinder head.

    2. Select a new guide bush (STD or O/S 0.05).

      Select a new guide bush (STD or O/S 0.05).
      Bush bore diameter Bush size
      13.004 - 13.025 mm (0.5120 - 0.5128 in.) Use STD
      13.054 - 13.075 mm (0.5139 - 0.5148 in.) Use O/S 0.05

      If the bush bore diameter of the cylinder head is greater than 13.025 mm (0.5128 in.), machine the bush bore to this dimension of 13.054 - 13.075 mm (0.5139 - 0.5148 in.).

      If the bush bore diameter of the cylinder head is greater than 13.075 mm (0.5139 in.), replace the cylinder head.

    3. A01KEC0E01

      Using SST and a hammer, tap in a new guide bush to the specified protrusion height.

      SST
      09201-10000   ( 09201-01080 )
      09950-70010   ( 09951-07100 )
      Protrusion height
      10.8 - 11.2 mm (0.425 - 0.441 in.)
    4. A01KICLE01
      Text in Illustration
      *1 8.0 mm Reamer

      Using a sharp 8.0mm reamer, ream the guide bush to obtain the standard specified clearance (See step Click here) between the guide bush and valve stem.

  3. REPAIR INTAKE VALVE SEATS


    1. A01KGH4E04

      If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.

    2. A01KEAUE03

      If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.

    3. A01KGJ9

      Hand-lap the valve and valve seat with an abrasive compound.

    4. After hand-lapping, clean the valve and valve seat.

  4. REPAIR EXHAUST VALVE SEATS


    1. A01KGH4E05

      If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat.

    2. A01KEAUE04

      If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat.

    3. A01KGRK

      Hand-lap the valve and valve seat with an abrasive compound.

    4. After hand-lapping, clean the valve and valve seat.

  5. INSTALL TIGHT PLUG


    1. A01KGGAE01
      Text in Illustration
      *1 Adhesive

      Apply adhesive to the tight plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

    2. Using SST and a hammer, tap in a new tight plug as shown in the illustration.

      Position A:

      SST
      09950-60010   ( 09951-00250 )
      09950-70010   ( 09951-07100 )

      Position B:

      SST
      09950-60010   ( 09951-00300 )
      09950-70010   ( 09951-07100 )

      Position C:

      SST
      09950-60010   ( 09951-00450 )
      09950-70010   ( 09951-07100, 09951-07100 )
      A01KGEHE01
      Text in Illustration
      *a Front Side *b Cylinder Head Cover Side
      *c Rear Side *d Intake Manifold Side
      *e Stops - -

  6. INSTALL STUD BOLT

    A01KF5JE01
    Text in Illustration
    *a Intake Manifold Side *b Cylinder Head Cover Side
    *c Exhaust Manifold Side - -
    Torque:
    A
    6.0 N*m  { 60 kgf*cm, 53 in.*lbf }
    B
    12 N*m  { 120 kgf*cm, 9 ft.*lbf }
    C
    26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  7. INSTALL RING PIN

    A01KEBJE01
    Text in Illustration
    *a Front Side *b Cylinder Head Cover Side
    *c Until pin stops - -

  8. INSTALL SEMICIRCULAR PLUG


    1. A01KELEE01
      Text in Illustration
      *a Seal Packing

      Remove any old packing (FIPG) material.

    2. Apply seal packing to the semi-circular plug as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

    3. Install the semi-circular plug to the cylinder head.

  9. INSTALL COMBUSTION CHAMBER SUB-ASSEMBLY


    1. A01KEI4E01
      Text in Illustration
      *a No. 1
      *b No. 2
      *c No. 3
      *d No. 4
      *e Mark 1, 2 or 3
      *f Front

      Select the number of shim, depending on the table below.

      Number mark of cylinder head Number of shim
      1 0
      2 0
      1
      3 1
      2
      Shim thickness
      0.03 mm (0.0012 in.)
    2. A01KGTX

      Align the combustion chamber knock pin with the cylinder head notch.

    3. Using a plastic-faced hammer, tap in the combustion chamber.

    4. A01KHZQ

      Using a dial indicator, check the combustion chamber protrusion.

      Combustion chamber protrusion
      Minus 0.03 - Plus 0.03 mm (Minus 0.0012 - Plus 0.0012 in.)

      If the protrusion is less than specified, adjust with shims.

      If the protrusion is greater than specified, replace the chamber and recheck the protrusion.

  10. INSTALL VALVE STEM OIL O SEAL OR RING

  11. INSTALL INTAKE VALVE


    1. A01KIJXE01

      Install the valve, spring seat, compression spring and spring retainer.

    2. Using SST, compress the compression spring and place the 2 keepers around the valve stem.

      SST
      09202-70020   ( 09202-00030 )
    3. A01KHEL

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

      Note

      Be careful not do damage the valve stem tip.

  12. INSTALL EXHAUST VALVE


    1. A01KFEZE01

      Install the valve, spring seat, compression spring and spring retainer.

    2. Using SST, compress the compression spring and place the 2 keepers around the valve stem.

      SST
      09202-70020   ( 09202-00030 )
    3. A01KEUP

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

      Note

      Be careful not do damage the valve stem tip.

  13. INSTALL VALVE LIFTER


    1. Install the valve lifter and shim.

    2. Check that the valve lifter rotates smoothly by hand.