CYLINDER HEAD REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

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

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PROCEDURE


  1. INSTALL SPARK PLUG TUBE

    Note

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


    1. A01M228C02
      *a 1.0 to 3.0 mm (0.0394 to 0.118 in.)
      *b 1.0 to 13.0 mm (0.0394 to 0.512 in.)

      Apply adhesive to 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 of 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 the spark plug tube.

    2. A01LXWGC03
      *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
      122 mm (4.80 in.)

      Note

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

  2. INSTALL NO. 2 STRAIGHT SCREW PLUG

    Note

    If water leaks from the No. 2 straight screw plug or the plug is corroded, replace it.


    1. A01LYL4

      Using a 10 mm straight hexagon wrench, install 3 new gaskets and the 3 No. 2 straight screw plugs.

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

  3. INSTALL VALVE SPRING SEAT


    1. Install the valve spring seats to the cylinder head.

  4. INSTALL VALVE STEM OIL SEAL


    1. A01M28OC09
      *a Intake side
      *b Exhaust side
      *c Gray
      *d Black

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

      Note

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

      Tech Tips

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

    2. A01LX89C03
      *a Correct
      *b Incorrect

      Using SST, push on the valve stem oil seal.

      SST
      09201-41020

      Note

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

  5. INSTALL INTAKE VALVE

    Tech Tips

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

    Type Compression Spring Shape
    A Straight
    B Tapered
    A01LYN0C01
    *A Type A
    *B Type B
    *1 No. 1 Valve Rocker Arm Sub-assembly
    *2 Valve Spring Retainer
    *3 Compression Spring
    *4 Valve Lash Adjuster Assembly

    1. Type A:


      1. Place the cylinder head on wooden blocks.

      2. A01LYALC04
        *a 30 mm (1.18 in.) or more

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

      3. Install the intake valve, inner compression spring and valve spring retainer to the cylinder head.

        Note

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

      4. A01M2D1N05

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

        SST
        09202-70020   ( 09202-00010 )
      5. A01LVIU

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

        Note


        • Be careful not to damage the intake valve stem tip.

        • Be careful not to damage the valve spring retainer.

    2. Type B:


      1. Place the cylinder head on wooden blocks.

      2. A01LYALC06
        *a 30 mm (1.18 in.) or more

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

      3. A01M1GOC01
        *1 Compression Spring
        *2 Valve Spring Retainer
        *3 Cylinder Head
        *4 Upper Side

        Install the intake valve, inner compression spring and valve spring retainer to the cylinder head.

        Note


        • Install the compression spring with its taperside facing upward (towards the valve spring retainer).

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

      4. A01LWTEC01
        *a Wooden Block

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

        SST
        09202-70020
      5. A01M1XS

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

        Note


        • Be careful not to damage the intake valve stem tip.

        • Be careful not to damage the valve spring retainer.

  6. INSTALL EXHAUST VALVE

    Tech Tips

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

    Type Compression Spring Shape
    A Straight
    B Tapered
    A01LYN0C01
    *A Type A
    *B Type B
    *1 No. 1 Valve Rocker Arm Sub-assembly
    *2 Valve Spring Retainer
    *3 Compression Spring
    *4 Valve Lash Adjuster Assembly

    1. Type A:


      1. Place the cylinder head on wooden blocks.

      2. A01LZFMC03
        *a 30 mm (1.18 in.) or more

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

      3. Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head.

        Note

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

      4. A01LW1NN09

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

        SST
        09202-70020   ( 09202-00010 )
      5. A01LY3F

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

        Note


        • Be careful not to damage the exhaust valve stem tip.

        • Be careful not to damage the valve spring retainer.

    2. Type B:


      1. Place the cylinder head on wooden blocks.

      2. A01LZFMC04
        *a 30 mm (1.18 in.) or more

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

      3. A01M1GOC01
        *1 Compression Spring
        *2 Valve Spring Retainer
        *3 Cylinder Head
        *4 Upper Side

        Install the exhaust valve, inner compression spring and valve spring retainer to the cylinder head.

        Note


        • Install the compression spring with its taperside facing upward (towards the valve spring retainer).

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

      4. A01LXD9C01
        *a Wooden Block

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

        SST
        09202-70020
      5. A01LW03

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

        Note


        • Be careful not to damage the exhaust valve stem tip.

        • Be careful not to damage the valve spring retainer.

  7. INSTALL VALVE STEM CAP


    1. Apply a light coat of engine oil to the valve stem ends.

    2. Install the 16 valve stem caps.

      Tech Tips

      Do not drop the valve stem caps into the cylinder head sub-assembly.

  8. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Inspect each valve lash adjuster assembly before installing it.

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    2. Install the 16 valve lash adjuster assemblies to the cylinder head.

      Note

      Install the valve lash adjuster assembly to the same place it was removed from.

  9. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. A01LXSDC03
      *1 Valve Lash Adjuster Assembly
      *2 No. 1 Valve Rocker Arm Sub-Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

      Apply engine oil to the valve lash adjuster assembly tips and valve stem cap ends.

    2. Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.