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. A01KG2R

      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
      10.985 - 11.006 mm (0.4325 - 0.4333 in.) Use STD
      11.035 - 11.056 mm (0.4344 - 0.4353 in.) Use O/S 0.05

      If the bush bore diameter of the cylinder head is greater than 11.006 mm (0.4333 in.), machine the bush bore to this dimension of 11.035 - 11.056 mm (0.4344 - 0.4353 in.).

      If the bush bore diameter of the cylinder head is greater than 11.056 mm (0.4353 in.), replace the cylinder head.

    3. A01KF17E01

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

      SST
      09201-10000   ( 09201-01060 )
      09950-70010   ( 09951-07100 )
      Protrusion height
      10.3 - 10.7 mm (0.406 - 0.421 in.)
    4. A01KI07E01
      Text in Illustration
      *1 6.0 mm Reamer

      Using a sharp 6.0mm 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. A01KI0X

      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
      10.985 - 11.006 mm (0.4325 - 0.4333 in.) Use STD
      11.035 - 11.056 mm (0.4344 - 0.4353 in.) Use O/S 0.05

      If the bush bore diameter of the cylinder head is greater than 11.006 mm (0.4333 in.), machine the bush bore to this dimension of 11.035 - 11.056 mm (0.4344 - 0.4353 in.).

      If the bush bore diameter of the cylinder head is greater than 11.056 mm (0.4353 in.), replace the cylinder head.

    3. A01KHR6E01

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

      SST
      09201-10000   ( 09201-01060 )
      09950-70010   ( 09951-07100 )
      Protrusion height
      10.3 - 10.7 mm (0.406 - 0.421 in.)
    4. A01KHH3E01
      Text in Illustration
      *1 6.0 mm Reamer

      Using a sharp 6.0mm 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. A01KGH4E01

      If the seating is too high on the valve face, use 25° and 45° cutters to correct the seat.

    2. A01KEAUE01

      If the seating is too low on the valve face, use 70° and 45° cutters to correct the seat.

    3. A01KH8E

      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. A01KGH4E02

      If the seating is too high on the valve face, use 25° and 45° cutters to correct the seat.

    2. A01KEAUE02

      If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat.

    3. A01KFQI

      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 a new tight plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

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

      Position A

      SST
      09950-60010   ( 09951-00200 )
      09950-70010   ( 09951-07100 )

      Position B

      SST
      09950-60010   ( 09951-00230 )
      09950-70010   ( 09951-07100 )

      Position C

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

      Position D

      SST
      09950-60010   ( 09951-00350 )
      09950-70010   ( 09951-07100 )
      A01KGHXE03
      Text in Illustration
      *a Front Side *b Intake Manifold Side
      *c Rear Side *d Stops

  6. INSTALL STUD BOLT

    A01KH2UE01
    Text in Illustration
    *a Front Side *b Cylinder Head Cover Side
    *c Intake Manifold Side *d Exhaust Manifold Side
    Torque:
    A
    26 N*m  { 265 kgf*cm, 19 ft.*lbf }
    B
    15 N*m  { 150 kgf*cm, 11 ft.*lbf }
    C and E
    5 N*m  { 50 kgf*cm, 44 in.*lbf }
    D
    7 N*m  { 70 kgf*cm, 62 in.*lbf }

  7. INSTALL RING PIN

    A01KHZWE01
    Text in Illustration
    *a Intake Manifold Side *b Cylinder Head Cover Side
    *c Until pin stops - -

  8. INSTALL W/HEAD STRAIGHT SCREW PLUG NO.1


    1. Apply adhesive to the end of the screw plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

    2. Using a 6 mm hexagon wrench, install the screw plug.

      A01KEIJE01
      Text in Illustration
      *1 Adhesive - -
      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  9. INSTALL SEMICIRCULAR PLUG


    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the semicircular plug and cylinder head.


      1. Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing grooves.

      2. Thoroughly clean all components to remove all the loose material.

      3. Using a non-residue solvent, clean both sealing surfaces.

    2. Apply seal packing to the oil seal retainer as shown in the illustration.

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

      1. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.

      2. Immediately remove nozzle from the tube and reinstall cap.

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

      A01KH9YE01
      Text in Illustration
      *1 Seal Packing - -

  10. INSTALL VALVE STEM OIL O SEAL OR RING


    1. A01KHNDE01

      Using SST, push in a new oil seal.

      SST
      09201-41020

  11. INSTALL INTAKE VALVE


    1. A01KG1ME01

      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
      09202-00020
    3. A01KGR8

      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. A01KEI5E01

      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
      09202-00020
    3. A01KFWO

      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.