CYLINDER HEAD (for DPF) 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 STUD BOLT

    Tech Tips

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


    1. Install the stud bolts.

      Torque:
      for stud bolt A and D
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      for stud bolt B
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
      for stud bolt C
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }
      for stud bolt E
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      A01DZYXE01
      Text in Illustration
      *1 Stud Bolt A *2 Stud Bolt B
      *3 Stud Bolt C *4 Stud Bolt D
      *5 Stud Bolt E - -
      *a Front Side *b Intake Manifold Side
      *c Cylinder Head Cover Side *d Exhaust Manifold Side

  2. INSTALL NO. 1 STRAIGHT SCREW PLUG

    Tech Tips

    If a No. 1 straight screw plug is corroded, replace it.


    1. Apply adhesive to the end of each No. 1 straight screw plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Using a 6 mm hexagon wrench, install the No. 1 straight screw plugs.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      A01E2BTE02
      Text in Illustration
      *1 Adhesive - -

  3. INSTALL SEMICIRCULAR PLUG


    1. Remove any old seal packing (FIPG material).

    2. 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 after applying the seal packing.

      • Prevent seal packing from adhering to the camshaft thrust groove.

    3. Install the semicircular plug to the cylinder head.

      A01DWU0E02
      Text in Illustration
      *1 Seal Packing - -

  4. INSTALL INTAKE VALVE STEM OIL SEAL


    1. A01DZ0WE01

      Using SST, push in a new oil seal.

      SST
      09201-41020

  5. INSTALL EXHAUST VALVE STEM OIL SEAL


    1. Using SST, push in a new oil seal.

      SST
      09201-41020

  6. INSTALL INTAKE VALVE


    1. A01DWZ4E01
      Text in Illustration
      *a 30 mm (1.18 in.) or more

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

    2. A01DYJ2E01

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

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

      SST
      09202-70020
      09202-00020
    4. A01E2V2E01

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

      Note

      Be careful not to damage the valve stem tip.

  7. INSTALL EXHAUST VALVE


    1. A01DWZ4E01
      Text in Illustration
      *a 30 mm (1.18 in.) or more

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

    2. A01DZZ0E01

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

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

      SST
      09202-70020
      09202-00020
    4. A01DYWIE01

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

      Note

      Be careful not to damage the valve stem tip.