CYLINDER HEAD REASSEMBLY

CAUTION / NOTICE / HINT

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.

PROCEDURE


  1. INSTALL STUD BOLT

    Tech Tips

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


    1. Install the stud bolts to the cylinder head sub-assembly.

      Torque:
      for stud bolt A
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
      for stud bolt B
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      for stud bolt C
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
      A01SBUXC01
      *a Intake Manifold Side *b Exhaust Manifold Side
      *c Cylinder Head Cover Sub-assembly Side *d 23.5 mm (0.925 in.)
      *e 12 mm (0.472 in.) *f 44.5 mm (1.75 in.)
      *g 14 mm (0.551 in.) *h 11 mm (0.433 in.)
      *i 36 mm (1.42 in.) *j 9 mm (0.354 in.)
      *k 25 mm (0.984 in.) - -

  2. INSTALL SEMICIRCULAR PLUG


    1. Remove any old packing (FIPG material).

    2. A01SAOXC02
      *a Seal Packing

      Apply seal packing to the semicircular plug as shown in the illustration.

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

      Note


      • The semicircular plug must be installed within 3 minutes from the completion of applying the seal packing.

      • Prevent seal packing from being stuck to the camshaft thrust groove.

    3. Install the semicircular plug to the cylinder head sub-assembly.

  3. INSTALL COMBUSTION CHAMBER SUB-ASSEMBLY


    1. A01SA9ZC01
      *a Front
      *b No. 1 Combustion Chamber
      *c No. 2 Combustion Chamber
      *d No. 3 Combustion Chamber
      *e No. 4 Combustion Chamber
      *f Mark 1, 2 or 3

      Select the number of shim, according to the table below.

      Select a New Combustion Chamber
      Item Specified Condition
      Mark 1 5.91 to 5.94 mm (0.2327 to 0.2338 in.)
      Mark 2 5.94 to 5.97 mm (0.234 to 0.235 in.)
      Mark 3 5.97 to 6.0 mm (0.235 to 0.236 in.)
    2. A01SCIAC02
      *a Combustion Chamber Knock Pin

      Align the combustion chamber knock pin with the cylinder head sub-assembly notch.

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

    4. A01SBSE

      Using a dial indicator, check the combustion chamber protrusion.

      Combustion chamber protrusion
      -0.03 to 0.03 mm (-0.00118 to 0.00118 in.)

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

      If the protrusion is more than the specification, replace the combustion chamber sub-assembly and recheck the protrusion.

  4. INSTALL INTAKE VALVE STEM OIL SEAL


    1. A01SB7KE02

      Using SST, push in a new intake valve stem oil seal to the intake valve guide bush.

      SST
      09201-41020

  5. INSTALL EXHAUST VALVE STEM OIL SEAL


    1. A01SB7KE02

      Using SST, push in a new exhaust valve stem oil seal to the exhaust valve guide bush.

      SST
      09201-41020

  6. INSTALL INTAKE VALVE


    1. A01SCIMC10
      *a 30 mm (1.18 in.) or more

      Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.

    2. A01SCO6E03

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

    3. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks to the valve stem.

      SST
      09202-70020   ( 09202-00030 )
    4. A01SBFFC02
      *a 5 mm Pin Punch

      Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

      Note

      Be careful not to damage the valve stem tip.

  7. INSTALL EXHAUST VALVE


    1. A01SCIMC10
      *a 30 mm (1.18 in.) or more

      Apply a sufficient coat of engine oil to the tip area of the exhaust valve shown in the illustration.

    2. A01SC6SE03

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

    3. Using SST, compress the inner compression spring and install the 2 valve spring retainer locks to the valve stem to the cylinder head sub-assembly.

      SST
      09202-70020   ( 09202-00030 )
    4. A01SDURC02
      *a 5 mm Pin Punch

      Using a 5 mm pin punch and plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

      Note

      Be careful not to damage the valve stem tip.

  8. INSTALL VALVE LIFTER


    1. Install the valve lifter and shim.

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