CYLINDER HEAD REASSEMBLY

PROCEDURE


  1. INSTALL SPARK PLUG TUBE

    Tech Tips

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


    1. B004N9HC01
      *a Adhesive
      *b Application Width
      *c Distance

      Apply adhesive to a new spark plug tube as shown in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      Standard Application Width
      1.0 to 7.0 mm (0.0394 to 0.276 in.)
      Distance
      1.0 mm (0.0394 in.)

      Note


      • Install the spark plug tube within 3 minutes of applying adhesive.

      • Be careful not to deform the spark plug tube.

      • Do not expose the spark plug tube to engine oil for at least 1 hour after installing it.

    2. B004JHBC01
      *a Protrusion Height

      Using a wooden block and hammer, tap in the 4 spark plug tubes to the specified protrusion height.

      Standard Protrusion Height
      75.7 to 76.7 mm (2.98 to 3.02 in.)

      Note

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

  2. INSTALL STUD BOLT

    Note

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


    1. B004JB9C01
      *a 20 mm (0.787 in.)
      *b 35 mm (1.38 in.)
      *c 13 mm (0.512 in.)

      Using an E8 "TORX" socket wrench, install the 7 stud bolts.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  3. INSTALL NO. 1 STRAIGHT SCREW PLUG

    Tech Tips

    If coolant leaks from a No. 1 straight screw plug or a plug is corroded, replace it.


    1. Apply adhesive to the 4 No. 1 straight screw plugs.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Install the No. 1 straight screw plugs within 3 minutes of applying adhesive.

    2. B0089EB

      Using a 6 mm straight hexagon wrench, install the 4 No. 1 straight screw plugs to the cylinder head sub-assembly.

      Torque:
      25 N*m  { 255 kgf*cm, 18 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. B004KBHC01
      *a Intake Valve Stem Oil Seal
      *b Exhaust Valve Stem Oil Seal
      *c Gold
      *d Gray

      Apply a light coat of engine oil to 16 new valve stem oil seals.

      Note

      Make sure to install each valve stem oil seal to the correct side. Installing an intake valve stem oil seal to the exhaust side or installing an exhaust valve stem oil seal to the intake side can cause installation problems later.

      Tech Tips

      The intake valve stem oil seals are gold and the exhaust valve stem oil seals are gray.

    2. B004HFQC01
      *a Correct
      *b Incorrect

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

      SST
      09201-41020

      Note


      • Failure to use SST will cause the valve stem oil seals to be damaged or improperly seated.

      • Do not push in the valve stem oil seals at an angle.

  6. INSTALL INTAKE VALVE


    1. B004NHZC01
      *a 30 mm (1.18 in.) or more

      Sufficiently apply engine oil to the tip area of the intake valve shown in the illustration.

    2. Install the 8 intake valves, 8 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.

    3. B004MNGN01

      Using SST, compress each compression spring and install the 8 valve spring retainer locks.

      SST
      09202-70020   ( 09202-01010, 09202-01020 )
      09202-00021
    4. B004OBN

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

      Note


      • Be careful not to damage the valve stem tip.

      • Be careful not to damage the valve spring retainer.

  7. INSTALL EXHAUST VALVE


    1. B004O2RC01
      *a 30 mm (1.18 in.) or more

      Sufficiently apply engine oil to the tip area of the exhaust valve shown in the illustration.

    2. Install the 8 exhaust valves, 8 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.

    3. B004KI6N02

      Using SST, compress each compression spring and install the 8 valve spring retainer locks.

      SST
      09202-70020   ( 09202-01010, 09202-01020 )
      09202-00021
    4. B004JG1

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

      Note


      • Be careful not to damage the valve stem tip.

      • Be careful not to damage the valve spring retainer.