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. B003YA5C08
      *a 2.0 mm (0.079 in.)
      *b 4.0 mm (0.157 in.)

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

      Note

      Install the spark plug tube within 3 minutes after applying adhesive.

    2. B003YSUC01
      *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" sockets, install the stud bolts.

      Torque:
      for bolt A, B, D
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }
      for bolt C
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
      B003YAWC02
      *a Intake Side *b Front Side
      *c Exhaust 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 (1.58 in)
      *m 29 mm (1.14 in) - -

  3. INSTALL NO. 1 STRAIGHT SCREW PLUG


    1. B003YQ2

      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. B003Y3PC09
      *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

      Pay attention when installing the intake valve stem oil seals 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 seals are gray and the exhaust valve stem oil seals are black.

    2. B003YQRC02
      *a Correct
      *b Incorrect

      Using SST, push in the 16 valve stem oil seals.

      SST
      09201-41020

  6. INSTALL INTAKE VALVE

    Tech Tips

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

    B003Y0JC01
    *A Type A
    *B Type B
    Type Inner Compression Spring Shape
    A Straight
    B Taper

    1. B003XT0C01
      *a 30 mm (1.18 in.) or more

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

    2. Type A:


      1. 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.

      2. B003YARN03

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

        SST
        09202-70020   ( 09202-00010 )

    3. Type B:


      1. B003XPNC02
        *a Narrow
        *b Wide

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

        Note


        • Install the inner compression spring with its taper side facing upward (towards the valve spring retainer).

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

      2. B003XQON01

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

        SST
        09202-70020
    4. B003YN2

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

      Note

      Be careful not to damage the retainer.

  7. INSTALL EXHAUST VALVE

    Tech Tips

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

    B003Y0JC01
    *A Type A
    *B Type B
    Type Inner Compression Spring Shape
    A Straight
    B Taper

    1. B003XT0C01
      *a 30 mm (1.18 in.) or more

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

    2. Type A:


      1. 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.

      2. B003YFJN01

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

        SST
        09202-70020   ( 09202-00010 )

    3. Type B:


      1. B003XPNC02
        *a Narrow
        *b Wide

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

        Note


        • Install the inner compression spring with its taper side facing upward (towards the valve spring retainer)

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

      2. B003YEDN01

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

        SST
        09202-70020

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

      Note

      Be careful not to damage the retainer.